Ajax DPC-2803 PDF

Operation
Maintenance
Parts
Composite Manual
DPC-2803
Compressor
Contract No. 9797

Serial No. 84564
Built For: ANDINA
Warnings, Cautions, and Notes
These safety instructions and procedures are to prevent injury in the operation and
maintenance of Ajax-Superior engines, compressors, and auxiliary equipment. These safety
procedures should not be considered as the only precautions to be taken. Good judgement
and careful safety practices should always be used.
Do Not Operate Or Attempt To Repair This Equipment Unless You Have Had The Proper
Training Approved By Ajax-Superior. For Training Information, Contact The Cooper Energy
Services Training Department In Mount Vernon, Ohio 43050 At (614)393-8200.
A NOTE indicates an essential operating procedure or condition which must be highlighted.

A NOTE may appear as follows:
Note
When changing the engine lubricating oil, also change the oil filters.
A CAUTION indicates that if the specified precaution is not heeded, damage to equipment
and /or minor personal injury may result. A CAUTION may appear as follows:
Caution
To insure against any hazardous malfunction of this equipment, always use the specified
parts when making repairs.
A WARNING indicates that if the specified precaution is not heeded, there is a sul2staiitiál.
risk of serious injury or death along with damage to property. A WARNING may appear as
follows:
Warning
The ignition system produces extremely high voltage. Do not touch high tension ter-
minals when the engine is operating.
Some general precautions that should always be practiced when operating or maintaining
the equipment are Usted in the following pages. Make sure that all personnel read these
precautions and adhere to them.
Cooper Energy Service: III Afax-Superior
Page 1
SUPERIOR'
General Maintenance Information

1. Follow all safety rules and operating procedures put in place by the company that owns
and operates this equipment.
2. Read and understand the instruction manual prior to operating this equipment to
become familiar with the safety, design, and operating features. If you do not have a
manual, call Ajax-Superior at (513) 3274200.
3. Always wear safety glasses or goggles, steel-toe safety shoes, and hearing protection.
Note: Other equipment may be required by the equipment owner.
4. Do not wear loose fitting clothing, neckties, scarves, watches, rings, etc., near operating
equipment as they can be caught in the moving machinery. Keep long hair tied back.
5. Locate nearest fire extinguisher to area where maintenance is to be performed. Ensure a
clear path to fire extinguisher in case it should be needed for an emergency situation.
6. Do not open cooling or lubrication systems when engine or compressor is hot, as steam or
hot liquids can be released, which can cause severe burns. Be aware that some surfaces
can remain hot for several hours atter the unit has been shutdown.
7. When draining the coolant and lubricants, prevent contamination of the environment by
the equipment fluids. Refer to equipment owner's material safety data sheets for
additional information. (Remember: Antifreeze/Glycol solutions, as well as most
lubricants, are flammable.)
8. Keep the area around the unit clean and orderly with ample space to walk safely around
the unit. Clean up spilLs and leaks quickly to prevent accidents caused by slipping and
falling.
9. Use only non-flammable, non-toxic cleaning solvents. NEVER USE GASOLINE OR
OTHER FLAMMABLE PRODUCTS FOR CLEANING PURPOSES. REFER TO
EQUIPMENT OWNER'S MATERIAL SAFETY DATA SHEETS FOR EACH CLEANING
PRODUCT FOR ADDMONAL PRECAUTIONS.
10.Use fans, blowers, etc. during maintenance and clean-up work in enclosed areas to
remove fumes from cleaning solvents and vented gases.
11. Use ladders, platforms, etc. where possible when working on elevated work surfaces.
Always stand on stable surfaces when working on this equipment.
12. Before starting any equipment, make sure all nearby personnel are aware of the start up
and are dear of the equipment.
13. Do not use bare hands when checking for leaks of fluids under pressure, as fluids or
particles can penetrate skin. Use cardboard or a similar material to check for leaks.
Cooper Energy Services ■ Alax-Superior
Page 2
Engine Maintenance
1. Shut down the engine first, then prevent it from being started before the work is done.
Close the starting block valve and remove the tubing line to the starting pilot valve. THIS
IS VERY IMPORTANT IF THE UNIT HAS REMOTE START CAPABILITY - a remote
operations center may try to start a unit without knowing that work is being performed
on it. Note: After maintenance work is done, some adjustments may need to be done
with the engine running. Stay clear of moving parts and follow instruction manual
procedures as required.
2. Shut down the engine by SHUTTING OFF THE FUEL SUPPLY. Do not ground the
ignition system to shut down a spark gas engine. This can leave an explosive mixture in
the engine and exhaust system.
3. Do not remove engine cover doors immediately alter shutdown. This can cause a sudden
inrush of atmospheric air and resta in an explosive mixture in the crankcase. Allow the
engine to cool until cover doors can be removed with bare hands.
4. Check all safety shutdown devices (overspeed, low oil pressure, high jacket water
temperature, vibration, etc.) according to the procedure and schedule in the maintenance
section of this manual.
5. After completion of maintenance work, reconrtectstarter pilot valve line and open block
valve. REMOVE MANUAL BARRING DEVICE, if used during maintenance.
6. Before attempting to start a gas engine, it must be cranked with the fuel and ignition off
to purge the exhaust system of combustible gases. The engine should be cranked for a
minlinum of 15 seconds before the ignition is turned on and then the fuel valve opened.
7. Be prepared to shut down the engine if an overspeed or other control malfunction occurs
on start up.
8. Before replacing any studs, measure stud height from machined surface and position
replacement stud to the same height.
Compressor Maintenance
1. Shut down the compressor first, then prevent it from being started before the work is
done. (See ENGINE MAINTENANCE section previously if engine driven.) If electric
motor driver, the electric power supply must be disconnected and locked out. TRIS IS
VERY IMPORTANT IF THE UNIT HAS REMOTE START CAPABILITY - a remote
operations center may try to start a unit without knowing that work is being performed
on it. Suction and discharge block valves (see site plan for location) must be closed to
prevent gas from flowing into the compressor during maintenance. (Gas pressure could
rotate the compressor and cause injury if not shut off and vented properly - see
Coopor Erwrgy Sondees ■ Afax-Superlor

Page 3
compressor section of manual.) Note: After maintenance work is done, some
adjustments may need to be done with the compressor running. Stay clear of moving
parts and follow instruction manual procedures as required.
2. Before attempting any maintenance or repair on the compressor, vent all gas pressure
from the cylinders, piping, and other pressurized components or chambers. Know the
piping system associated with this compressor. Open discharge blowdown and/or
bypass valves to vent system to atmosphere. ALLOW COMPRESSOR TO COOL FOR AT
LEAST 15 MINUTES BEFORE OPENING SUCTION OR INTERSTAGE VENTS.
Atmospheric air can be drawn in if a vaciaran exists and can create an explosive mixture.
CHECK LOCAL OR PANEL PRESSURE GAUGES FOR =RO READING BEFORE
REMOVING ANY GAS PASSAGE COMPONENTE SUCH AS VALVES, VALVE CAPS,
OR CYLINDER HEADS. Note: UNLOADER CONTROL PRESSURE IS TYPICALLY
NOT SHOWN ON GAUGES. Vent unloader control pressure line by loosening control
line tubing fitting.
3. IF POISONOUS OR SUFFOCATING GASES ARE BEING COMPRESSED, FOLLOW ALL
PLANT SAFETY PROCEDURES PRIOR TO AND DURING MAINTENANCE ON ANY
GAS EQUIPMENT OR PIPING TO AVOID 1NJURY OR DEATH DUE TO INHALATION
OF SUCH SUBSTANCES.
4. Regularly check around compressor and piping gaskets and joints for leaks which could
result in a fire or an explosion.
5. Test all pressure gauges on a periodic basis (see maintenance schedule) to ensure accurate
pressure readings. Likewise, check all relief valves for design opening pressure (see
manufacturer's data for each relief valve in packaging section of manual).
6. Check all safety shutdown devices (low oil pressure, high and low gas pressures,
vibration, etc.) per the schedule in the maintenance section of this manual.
7. Remove electrical lockout function if motor driven when maintenance is completed and
REMOVE MANUAL BARRING DEVICE, if used during maintenance, before starting
unit.
8. Before replacing any studs, measure stud height from machined surface and position
replacement stud to the same height.
ALL PERSONNEL SHOULD READ AND UNDERSTAND THE PREVIOUS SECTION ON

WARNINGS, CAUTIONS, AND NOTES.
Cooper Energy Services ■ Ajax-Superior
Page 4
Warranty
The Seller warrants to the Buyer that the equipment to be delivered hereunder will be free
from defects in material, workmanship and title and will be of the kind described in the
contract.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER

WARRANTIES WHETHER WRITTEN, ORAL OR IMPLIED (INCLUDING ANY
WARRANTY OF MERCHANTABILTTY OR FITNESS FOR PURPOSE).
If it appears within one year from the date the equipment is placed in service but no later
than eighteen (18) months from the date of delivery to the Buyer, whichever first occurs, that
the equipment does not meet the warranty specified aboye and the Buyer notifies the Seller
promptly, the Seller shall correct any defect, at the Seller's option, either by repairing any
defective part or parts or by making available, at the Seller's factory, a repaired or
replacement part. The liability of the Seller to the Buyer (except as to title) arising out of the
supplying of the equipment, or its use, whether on warranty, contract or negligence, shall not
in any case exceed the cost of correcting defects in the equipment or part thereof and upon
expiration of the warranty period all such liability shall terminate. The foregoing shall
constitute the sole remedy of the Buyer and the sole liability of the Seller.
The preceding paragraph shall not apply and the Seller assumes no liability whatsoever for
breach of warranty when there is evidence that the defect arose as the result of (a) abuse or
negligence in the operation of the equipment, (b) failure to maintain the equipment properly,
(c) overloading or overspeeding, or (d) use of repair parts not approved by Seller.
The warranty given to the Seller by its supplier of special equipment, including but not
limited to generators, is hereby assigned without recourse by the Seller to the Buyer.
AS TO THIS SPECIAL EQUIPMENT, WHICH GENERALLY BEARS THE NAMEPLATE

OF THE SELLERS SUPPLIER, THE SELLER ASSUMES NO LIABILTTY WHATSOEVER
FOR BREACH OF WARRANTY, WHETHER WRITTEN, ORAL OR IMPLIED
(INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
PURPOSE).
Coosm Energy Services ■ AJax•Suportor
Page 5
Vds: Instdiation Of Show,* And Flywhesi
COOPER
ENERGY SERVICES Engineering Sales &
Service Bulletin
Ajax-Superior Engines/
Oklahoma City, OK 73129 Compressors
ESS-F-961
Installation of Sheave and Flywheel

This bulletin applies to all Ajax models 2201, 2202, 2801, 2803, & 2804. The flywheels and sheaves of
these AJAX models are installed with a RINGFEDER locking device, which is inserted over the hub of
the flywheel (or sheave) and locks them to the crankshaft. The special procedures which must be
followed for installation and rernoval are as follows:
Installation
1. Clean the flywheel (or sheave) hub, bore and mating diameter on the crankshaft. Surfaces must be
dry and free of any burrs, rust or lubricants.
2. Remove RINGFEDER (collar, inner ring and locking screws) from shipping container. Check if
supplied locking screw threads, screw head bearing area, and the taper of the inner ring are
lubricated. If not, lubricate thern with a molybdenum disulfide grease, such as MolykoteGn Paste or
similar.
3. Slide Half Shrink Disk (collar and inner ring) over hub projection and push it to required position.
The hub outside diameter may be greased.
Note
When retrofitting ringfeder on a keyed shaft, ensure inner ring split is 180". from shaft keyway.
4. Put the locking screws with hardened washers through the web clearance holes and screw them into
the corresponding collar holes, finger tight. See Figure 1:
• Figure 1
Flywheel • Collar
Hardened
Washer Inner Ring
Crankshaft
Locking
Screw
00728
5. Slide hub over shaft to desired position.

6. Take any 3 or 4 locking screws equally spaced and snug them up to establish a parallel or
perpendicular position of the Shrink Disk collar relative to the hub web or shaft, respectively. This
will seat the collar on the taper of the Inner ring and avoid cocking of the collar.
Page 1 of 3 Released: 17 October 1996

TM*. Instalitdon Of Sheen And nywhe*
7. Using a torque wrench, tighten all locking screws gradually (no more than 1 / 2 turn ora each screw at
one time) and all the way around, in either a clockwise or a counterclockwise sequence (not in
diametrically opposite sequence). Several passes are required cantil all screws are torqued to the
specified tightening torque. See Table 1:
Table 1
Part Torque ft-

Hub of Unit Model
Number lbs
BM-11878-D-1 Sheave 2201, 2202, 2801, 2802, 2803, & 2804 185
BM-11878-D-2 Flywheel 2201, 2202, 2801, 2802 185
BM-11878-E-1 Flywheel 2803 185
BM-11878-E-2 Flywheel 2804 185
8. Check and make sure that no screw will turn anymore by applying specified tightening torque (see
Table 1). Only then is the installation completed.
9. After final tightening of screws, check flywheel run-out. See Figure 2 for maximum tolerances. If
run-out exceeds maximum, loosen all socket head screws and tap flywheel into position using a soft
hammer on wood block. Retighten screws following same sequence as before, and check that run-
out is within tolerance.
• Figure 2
Removal
1. Gradually release locking screws all the way around. Initially each screw should be released about a
quarter of a turn only. Thus tilting and jamming of the collar will be avoided.
Note
DO NOT remove locking screws completely at this time, otherwise collar muy spring off.
2. Any rust formed ádjacent to hub must be removed first. Once the screws are loose, pulí hub from
shaft.
Page 2 of 3 Releesed: 17 October 199€

ESS-F-911
Title: Installetion Ot Shern And Flywheel
Re-Installation
1. Upon removal of component, disassemble Shrink Disk. Clean and Inspect all parts. Reinstall
following the Installation procedure, beginning with Step 2 of the appropriate section.
Page 3 of 3 Release& 17 October 1996

et
ESS-F-963
Title: Keyless Flywheel Installation And Timing
COOPER
Service Bulletin
ESS-F-963
Keyless Flywheel Installation and Ignition Timing

This procedure applies to all Ajax models 2200 and 2800 series Ajax engines. It covers the installation of
the keyless ringfeder locking device fitted on flywheels on 2200 and 2800 series engines. The procedure
explains the method used to find top dead center (TDC) and proper ignition timing of the engine.
Installation
1. Stand the flywheel up on its edge, allowing access to both sides of the flywheel.
Caution
Firmly secure the flywheel to prevent it from falling over.
2. Remove the rust inhibitor paper from the inside of the machined split ring on the ringfeder. Remove
ringfeder (collar, inner ring, and locking screws) from shipping container. Verify that the supplied
locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. If not,
lubricate with molybdenum disulfide grease, such as Molykote GN paste or equivalent.
3. Place the green ringfeder and split ring assembly on the machined diameter of the flywheel.
4. The bolts to be used on the ringfeder are metric. A 16 mm (FWF2500-1600) hardened flat washer is
required for every bolt. Start each bolt into the ringfeder, but DO NOT TIGHTEN
Y Figure 1
5. Use a fine file or emery cloth to remove any burrs from the flywheel and crankshaft, cleaning both
for assembly.
6. Coat the flywheel and crankshaft sparingly with engine oil. The flywheel to crankshaft fit is between
.001"-.003". Do not over-lubricate.
Note
Step 6 should only be performed during initial engine assembly. Do not lubricate on field units.
7. Carefully place the flywheel on the end of the crankshaft. Do not bump the crank as this will create
a burr that can impede installation. Push the flywheel evenly onto the crankshaft until the face of the
Page 1 of 4 Released: 6/8/99

ESS-F-963
flywheel and the end of the crankshaft are even.
Note
Do not wiggle the flywheel in/out or try to turn the flywheel onto the crankshaft! It will create heat
and possibly gall the surface of the crankshaft.
8. After the flywheel is installed, snug several of the bolts in a criss-cross pattern to lock the flywheel to
the crankshaft.
9. Remove the crosshead side access door from power cylinder one.
10. Set the timing pointer on the ignition bracket, allowing 1/8" clearance from the flywheel. Adjust the
pointer until it is located in the middle of vertical slot on the bracket.
Finding TDC and Timing Degree Marks

11. Place a 4" bar or equivalent between the end of the crosshead and the pack flange. Bar the engine
over clockwise until the bar stops against the packing. Hold the flywheel in this position, keeping
the crosshead against the bar.
12. Mark the flywheel on the outer diameter (O.D.) with an ink marker at the pointer location. This is
"Temporary Mark #1".
13. Remove the tension on the bar in the crosshead and remove.
14. Rotate the engine clockwise until is has passed TDC far enough to re-insert the bar.
15. Reinsert the bar and rotate the engine counter-clockwise until the bar stops the crosshead against the
packing. Hold the flywheel in this position.
16. Mark the flywheel on the O.D. with an ink marker at the pointer location. This is "Temporary Mark
#2"
17. Release the tension from the bar and remove. Rotate the engine to allow access to both of the tempo-
rary marks.
18. Measure the distance between the marks. Divide the distance by two and, using an ink marker, cre-
ate a third mark equidistant between the two marks. This will be "Temporary Mark #T". Mark T
represents the Top Dead Center (TDC) of the crankshaft.
Note
You can verify the position of the TDC mark by measuring the distance between marks #1 and T, then
marks #2 and T. These distances should be equal.
19. It is now necessary to add the ignition timing mark. Verify that the ignition is properly set. All 2200
and 2800 engines use a 48" diameter flywheel. This means that:
♦3° = 1'4" Flywheel O.D. distance
♦9° = 33/4" Flywheel O.D. distance
♦11° = 4-5/8" Flywheel O.D. distance
20. Using one of the aboye distances, create a temporary mark on the flywheel to represent either 3°, 9°
or 11° (depending on model) before TDC or clockwise from the T mark on the flywheel.
21. Rotate the engine so that the timing mark is aligned with the flywheel pointer. This sets the crank-
shaft in the general range of normal ignition timing.
22. Use the nut and stud expanders to lock and hold the crankshaft in position. These should be
installed between the sheave and end cover. See Figure 2. This picture shows the method of locking
the crankshaft used during engine assembly. Alternate methods of locking are acceptable for field
installation.
23. Check that the timing mark is still aligned with the flywheel pointer. As a double check, verify that

ESS-F-963
the scribed line located on the end of the crankshaft is positioned below horizontal. See Figure 3.
24. Loosen the ringfeder bolts to free up the flywheel on the crankshaft.
V Figure 2
V Figure 3
End of Crankshaft
Power Cylinder Horizontal
Side

ESS-F-963
Titie: Keyless Flywheel Installation And Timing
COOPER
Service Bulletin
ESS-F-963
Setting Timing Of the Flywheel

25. Ensure that the ignition pickup coils are in the proper holes:
♦ 3° - Top Holes
♦ 9° - Two Holes From The Bottom
♦ 11° - Bottom Holes
26. Rotate the flywheel on the crankshaft, without moving the crankshaft itself, until the recessed rnag-
net is centered over the number 1 pickup coil. This is the "A" pickup coil or the one closest to the
power end.
27. While keeping the magnet aligned, re-tighten the ringfeder to the flywheel. Now place a permanent
timing mark on the flywheel and mark it either 3°, 9°, 11° accordingly.
28. Permanently mark the TDC location and then erase all of the temporary marks made on the fly-
wheel.
29. Remove all crankshaft locking devices and find TDC as in the aboye procedures to verify that the
TDC position and the ignition timing mark have been correctly located relative to the magnet posi-
tion.
30. When certain that the permanent marks are correct, tighten and torque all flywheel bolts.
31. Match mark the flywheel coincident with the scribe line on the end of the crankshaft using a chisel.
Stamp a "1" next to this mark.
32. Stamp the engine serial numbers on the crankshaft and hub of the flywheel.
33. Chisel mark a line on the OD of the flywheel at TDC. Metal stamp a "0" next to this mark.
34. Chisel mark a line at either the 3°, 9°, or 11° (depending on model) on the OD of the flywheel. Metal
stamp the correct timing value next to this mark.
35. It may be necessary after engine start-up to readjust the timing pointer. The pickup coil should be
centered over the cylinder #1 recessed magnet when the pointer is pointing at the timing mark.
2804 (DPC-800) Engines Only

These engines do not use flywheel magnets and pickup coils. When finished with Step 20 aboye go
directly to Step 29.The magneto should be adjusted via the slotted holes on the mounting flange until the
cylinder #1 is aligned with the flywheel timing marks.
Page 4 of 4 Released: 618199

ESS-G-98 1
AJAX GAS INJECTION VALVES
COOPER
ENERGY SERVICES
ENGINEERING SALES &
SERVICE BULLETIN
AJAX-SUPERIOR ENOIN!S/
OKLAHOMA CITY, OK 73129 COMPRESSORS
ESS-G-981
Date: July 22, 1998

PRODUCT IMPROVEMENT UPDATE
Ajax Product Division would like to announce several product improvements in the
design of our gas injection valve assemblies. Assemblies affected by these changes are:
YAE-5098-T Series & YAE-5098-Y Series gas injection valve assemblies.
Components affected:
SPRINGS:
Gas valve spring P/N BM-10869-A has been superceded by P/N BM-10869-B.
The new BM-10869-B spring has a longer free length than the A. The increase in free
length doubles the pre-load on the spring allowing the gas valve to open & close more
precisely during the fuel injection cycle. This prevents any admission of fuel gas outside
the predetermined timing that the valve is designed to be opened.
The new spring can be physically identified with a free length of 2-7/8 versus the A
springs free length of 2-9/16.
WARM/NIG!: It is very important not to mix the new BM-10869-B springs with the A
spring on multi-cylinder engines. Also, the BM-10869-B spring should not be used on
the plunger pump assembly in the engines control box. The original A spring is still
utilized here.
1 Issued 07/98 •
ESS-G-98 r
VALVE GUIDE:
The gas injection valve guide P/N K-7891-A has been superceded by P/N K-7891-B.
The new K-7891-B valve guide has a pre-drilled grease communication hole eliminating
the requirement to drill the guide once it is pressed into the valve housing. When
installing the new guide, align pre-drilled hole with the grease-fitting hole in the valve
housing. There is a milled arca surrounding the communication hole on the outside of the
guide to allow variations in guide height once installed in the valve housing.
NOTE: Before removing old guide, note length (15/16) extending out of valve
housing and install the new guide with same extension.
The bore of the guide now has spiral grooves machined into it to allow a path for grease
to communicate throughout the length of the guide. The bore of the guide has also been
increased to prevent any possibilities of valve stem interference (sticking) due to
variations in valve housing bores. Use a 7/16 reamer and ream the guide before and after
installation into the valve housing. It is very important to clean the guide bore thoroughly
after final reaming as metal cuttings will migrate into the lube slots and will be pushed
into the bore when greasing.
2 Issued 07/98
TM*: Ajax Mixing Valva
COOPER
Service Bulletin
AJax-Superior Engines/
ESS-M-961
Ajax Mixing Valves
General
Design improvements have been made to the valve seats which are a component part of valve manifolds
YAE-10510-A, YAE-7510-B, YAE-6010-D, and YAE-6010-C. These seats holds the mixing valve in
position through a combination of a tapered pin and stop valve. The tapered pin fits into a reamed hole
that is drilled thru the valve seat holding the stop valve in position. On this design, it was possible for
the tapered pin to come loose and fall into the scavenging chamber. This, in turn, could allow the
mixing valve to work it's way out of the valve manifold assembly and also fall into the chamber.
To avoid this potential risk, the design of the valve manifold assemblies has been changed. The
improved design uses a drilled hole on the valve seat of a specific depth in place of the drilled thru
reamed hole. This allows a roll pin to be used in place of the tapered pin, providing a more precise fit
and preventing components from working loose during engin operation.
• Figure 1
Valve Manifold
Assembly
It is recommended that the valve seats or assemblies be updated to the new design when possible. This
can be done by replacing the old valve seat with the updated valve seat or by replacing the entire valve
manifold assembly.

This: Ajaa Mixing VI;
Table 1 Valve Seat Part Numbers
Old Part Number Old Name New Part Number New Name
A-4527 Valve Seat A-4527-2 Vaive Seat
A-4527-A Valve Seat A-4527-A-1 Vaive Seat
A-4527-B-1 Valve Seat A-4527-B-2 Vaive Seat
A-4527-C Valve Seat A-4527-C-1 VaIm Seat
Table 2 Valve Manifold Part Numbers

Old Part Number Old Name New Pan Number New Name
YAE-10510-A Vatve Manifold Assembly YAE-10510-A-1 Valva Manifold Assembly
YAE-7510-B Vaive Manifold Assembly YAE-7510-B-1 Valva Manifold Assembly
YAE-6010-0 Valve Manifold Assembly YAE-6010-D-1 Valve Manifold Assembly
YAE-6010-C Valva Manifold Assembly YAE-6010-C-1 Valva Manifold Assembly

ESS-S-992
E
Title: Spark Plug Lubricant
COOPER
Service Bulletin
ESS-S-992
Spark Plug Lubricant

It has been brought to our attention that there have been incidences of spark plugs seizing in the power
cylinder heads and the jet cell ignitors on Ajax units. This can create costly replacement, repairs, or
down time. To reduce the possibility of this occurrence, Ajax recommends the use of a high temperature,
non-conductive, non-metallic thread lubricant.
One of the products that fits these requirements is:

BG Service Corp. Mica Lubricant
♦ A718 (4 oz. can)
♦ A719 (16 oz. can)
♦ A768 (32 oz. can)
This product can be purchased at most automotive supply stores. The following procedure should be
maintained when replacing spark plugs:
1. Use a spark plug thread chaser (P/N 2-01T-028-002) to remove any build-up of debris.
2. Properly gap spark plug to Ajax recommendations.
3. Apply spark plug lubricant VERY SPARINGLY to the threads per the lubricant Manufacturer's
instructions (leave first thread dry).
4. Tighten spark plug to the proper torque:
5. Dry torque 60 ft. lbs
Lubricated torque 50 ft. lbs.
Steps To Follow In The Event Of A Seized Spark Plug

1. Do not force a spark plug if it starts to seize on the way out.
2. Ajax suggests the use of thread penetrating oil such as "Aerokroil" which is made by Kano Labrato-
ries.
3. Apply the penetrating oil per instructions on the container.
4. Wait a minimum of 5 minutes before trying to remove spark plug.
5. Slightly turning the spark plug in and out may help distribute the penetrant.
6. In some cases a second application may be needed.
7. If the aboye steps are unsuccessful, you may also try the following:
♦ Break the ceramic portion of the spark plug off and spray the plug core with freon or liquid nitro-
gen. This will shrink the plug enough to remove the plug without additional thread damage.

ESS-S-993
E
Title: Replacing Lip Seals With Oil Slingers
COOPER
Service Bulletin
ESS-S-993
Instructions For Replacing Lip Seals With Oil Slingers

(Field Replacements)
The oil seal on Ajax units prevents oil from migrating along the crankshaft to the exterior of the
crankcase.
FLYWHEEL END
1. Remove flywheel per TD-1325
2. Remove the end cover. Be careful of gaskets and gasket surfaces.
3. Remove the wear plate (K-8061) from the end cover.
4. Install the new slinger (K-8001) on the crankshaft by heating it to 350° F. Slide it solidly up against
the timing gear and allow it to cool in a safe location.
5. Using a firm straight edge, lay it across the end of the frame (old gasket on) and measure and record
the distance from the inside edge to the recess cut in the slinger. Record this value.
Note
Include the end cover gasket thickness when measuring the distance in Step 5.
6. Install the deflector (K-8009-1) and gasket (K-7223-D) on the end cover. Measure form the end of the
deflector to the end cover gasket. Subtract this distance from the distance measured in Step 5. Record
this value.
7. Subtract an additional 0.050" from the value calculated in Step 6. The result of this subtraction will
be the amount of shim thickness that is required.
8. Remove deflector and install the shim(s) (K-8051-B) and the deflector on the end cover. Use the new
longer capscrews (BM-11900-C-0420-14) and verify that they do not protrude ensure that they do not
protrude more than 2 threads.
Note
Verify that the oil drain holes are on the bottom.
9. Using wax or SOFT solder placed in the recess of the slinger to measure the distance between the
deflector and the slinger. Grease can be used to hold this material in place. Next, loosen the bolts
just enough to allow the end cover to be pulled back far enough to recover the wax or solder.
Caution
If the wax or soft solder use is too hard, it will disport the end plate and give a false reading. Do not
damage the slinger or deflector.
10. Measure thickness of the wax or solder. The proper clearance is 0.040-0.060". If incorrect, adjust
shim pack and re-check.
11. Verify that a new end plate gasket (K-7230) is in place before installing the top cover.
12. Position end cover so that the top is flush with the top cover.
Page 1 of 3 Released: 8116199
ESS-S-993
13. Loosen the deflector bolts and position deflector so that it is centered on the crankshaft, assuring that
it does not contact the crankshaft.
14. Tighten the deflector bolts.
SHEAVE END
1. Remove cooler guard, belts, damper and sheave.
2. Remove the end cover. Be careful of gaskets and gasket surfaces.
3. Remove the wear plate (K-8062) from the end cover.
4. Remove the spacer (K-8063) by heating carefully with a torch.
Caution
Take measures to protect the cooler end main bearing and ensure against fire from oil andlor oil fumes.
Have a fire extinguisher available; if necessary, remove the cooler end main bearing.
5. Instan the new slinger (K-8002) on the crankshaft by heating it to 350° F. Slide it solidly up against
the shoulder on the crankshaft and allow it to cool.
6. Using a firm straight edge, lay it across the end of the frame (oíd gasket on) and measure the dis-
tance from the inside edge to the recess cut in the slinger.
7. Instan the deflector (K-7224-A-1) and gasket (K-7223-C) on the end plate, along with the correct
amount of shim pack (K-8051-A) to result in a 0.040-0.060" clearance between the deflector and the
slinger.
8. Measure the distance from the end of the deflector to the end cover. Subtract this distance from the
distance measured in Step 6. Record this value
Note
Include the end cover gasket thickness when measuring the distance in Step 6.
9. Subtract 0.050 from the value determined in Step 9. The result is the amount of shim thickness
required.
10. Remove the deflector and install shims (K-8051-A) and deflector on end cover.
11. Use the new longer capscrews (BM-11900-C-040) and ensure that they do not protrude more than 2
threads.
Note
Verify that the oil drain boles are on the bottom.
12. Using wax or SOFT lead wire placed in the recess of the slinger, measure the distance between the
deflector and the slinger. Grease can be used to hold this material in place.
Note
If a soft medium is too hard, it will distort the end plate and give a false reading. Take care not to dam-
age the slinger or the deflector.
13. Instan the end cover, then loosen the bolts to that the end cover can be pulled back far enough to
recover the wax or lead, then measure it.
14. If the clearance requires adjusting, remove the end cover, adjust the shim pack and repeat step 7 until
the 0.040-0.060 inch clearance is achieved.
Note
The shim pack contains laminated shims which can be peeled off to obtain the proper thickness.
Page 2 of 3 Released: 8/16199

ESS-S-993
rÉ COOPER
Service Bulletin
ESS-S-993
15. Be sure to instail a new end plate gasket (P/N K-7230) before installing the end plate.
Note
Keep torch at a 90° angle to the spacer to prevent flames from migrating into crankcase or on to the
main bearing.
16. Position the end cover so that the top is flush with the top cover.
17. Loosen the deflector bolts and position deflector so that it is centered on the crankshaft, assuring that
it does not contact the crankshaft.
18. Tighten the deflector bolts.

AJAX COMPRESSOR COMPOSITE MANUAL
MODEL DPC-2803 COMPRESSOR CONTRACT 9797 SERIAL NUMBER 84564
NO. 1 CYLINDER 12" X 11" TYPE Dila: SERIAL NUMBER 12856
NO. 2 CYLINDER 12" X 11" TYPE YK11F SERIAL NUMBER 12857
DISTRIBUTOR AJAX P.O. NUMBER 0-00-05-004

CUSTOMER ANDINA
TABLE OF CONTENTS
PART NUMBER BULLETIN NUMBER
ENGINE
OPERATION & MAINTENANCE MANUAL
INTEGRAL ENGINE-COMPRESSORS
SPILLPORT GAS INJECTION
PARTS LIST
ENGINEERING-SALES-SERVICE-DATA-SOUR GAS ESS-G-751
IGNITION TROUBLE SHOOTING TD-1351
IGNITION SYSTEM SERVICE MANUAL AISM 5000
LUBRICATOR BM-21014-10
INSTRUCTIONS - PUMP MODEL 55
GOVERNOR AJAX/MECH. YK-6238-A
FUEL GAS SYSTEM

GAS PIPING DRAWING SK-8532-317
REGULATOR - HIGH PRESSURE 2040 5852
INSTRUCTION MANUAL - TYPE 630 FORM 1243
AUTOMATIC SHUTOFF VALVE - 2" BM-10974-D-5
INSTRUCTION BULLETIN PV-94129B
BLOCK VALVE 2549 2176
RELIEF VALVE - FUEL GAS 638128821109N 0100
INSTRUCTION BULLETIN 8100 SERIES
STARTING SYSTEM -(TDD

STARTING PIPING SPEC SPEC 15841-E-273
STARTING PIPING DRAWING SK-8532-611
STARTING MOTOR - TDI BM-11679-R-1
INSTALLATION & OPERATION MANUAL T1-702
STRAINER Y TYPE 2" BM-11794
BLOCK VALVE BM-16627-A
JACKET WATER SYSTEM

JACKET WATER SPEC SPEC 15360-L-552
JACKET WATER DRAWING SK-7940-665
WATER PUMP 5027 2825
OPERATION & MAINTENANCE 4846357
THERMOSTATIC CONTROL VALVES BM-11524-E-7
BULLETIN A-1530
WATER PUMP BELT 5V 1023 0114
JACKET WATER SYSTEM - (CONT.1

WATER PUMP SHEAVE 4535 1270
WATER PUMP IDLER 6300 6303
INLET AIR SYSTEM

AIR FILTER BM-16315-4
AIR FILTER ELEMENT BM-16315-12
MANOMETER BM-11831
COMPRESSOR
PERFORMANCE CURVE LETTER
PERFORMANCE CURVE INSTRUCTIONS TD-1201
PERFORMANCE CURVES
PARTS LIST - COMPRESSOR CYLINDERS
STEM SEALS FOR VARIABLE CLEARANCE POCKETS ESS-S-801
PROCESS GAS EQUIPMENT

RELIEF VALVE BM-21027D SERIES
BULETIN 9100 SERIES
SCRUBBER LEVEL CONTROLLER BM-16430-R
BULLETIN - L1200-N-DVO-R L12-9102B
SCRUBBER DUMP VALVE BM-15207-AA
BULLETIN DV-98110B
ASME U-1A DATA REPORTS (3) PRESSURE VESSELS
BALL VALVE 8" - 150# 2549 2620
BALL VALVE 6" - 300# 2549 2604
BALL VALVE 3" - 300# 2549 2310
PISTON CHECK VALVE 6" - 300# 7100 SERIES BULLETIN 2-8 11-8
COOLER AND DRIVE

COOLER DRIVE SPEC SPEC 7006-J-298
COOLER DRIVE BELTS 5V 1023 0150
COOLER DRIVE SHEAVE - 16" P.D. 4535 1478
COOLER DRIVE IDLER - 10.20 P.D. 4535 1495
COOLER SPECIFICATION SHEET S/N 00051
OPERATING & MAINTENANCE INSTRUCTIONS
SUGGESTED START-UP PROCEDURE
PARTS LIST
GENERAL INSTALLATION & MAINTENANCE IM-100
COOLER BELT DRIVE RECOMMENDATIONS TD-1272
PROCEDURE FOR GREASING FAN HUBS TD-1301
IDLER PULLEY ALIGNMENT TD-1350
ASME U-1A DATA REPORTS (1) COOLER SECT.
INSTRUMENTATION (MURPHY)
WIRING DIAGRAM - PANEL 50-30-2073
WIRING COLOR CODE SK-8507
PANEL TEST PROCEDURE - FIELD TD-1297
SELECTRONIC TATTLETALE - MARK III MK3-95052B
PRESSURE SWICHGAGES - OPL SERIES OPL-96001B
TEMPERATURE SWICHGAGES MDTM-8911B
TEMP SWITCH GAUGES 20-25 SERIES T-94031B
TACHOMETER SHD3-97050B
PULSATION DAMPNER PD-95145B
TEMPERATURE SCANNER TDX-9106B
VIBRATION SWITCH BM-15822 VS-94092B
LIQUID LEVEL SHUTDOWN - L1200 BM-16242-3
INSTALLATION & SPECIFICATIONS L12-9102B
INSTRUMENT GAS REGULATOR BM-16053-1
INSTRUCTIONS/PARTS LIST P-125
CRANKCASE OIL LEVEL CONTROLLER BM-10693-T
INSTALLATION & SPECIFICATIONS LC
CRANKCASE LOW OIL LEVEL SWITCH BM-10693-P
INSTALLATION & SPECIFICATIONS PS/ES
LUBRICATOR LOW OIL LEVEL SWITCH BM-10693-M-3
INSTALLATION & SPECIFICATIONS 507L
THERMOCOUPLE BM-15773-P, P-1
INSTALLATION, START-UP & MAINTENANCE

SETTING AND GROUTING INSTRUCTIONS TD-1277
RECOMMENDED STARTING PROCEDURE TD-1292
PREVENTATIVE MAINTENANCE TD-1344
PACKAGE DRAWING S
GENERAL ARRANGEMENT 2954-45
FOUNDATION PLAN 2336-G-261
MAX ENGIN{ ADJUITII{NT AND SPE(IfKATION IliffT
CONTRACT NUMBER: ENGINE SERIAL NUMBER: 8404
ENGINE MODEL: CUSTOMER: Andina/ Bolivia
Bore: is,o Strokt: 16.0
firilig Order: 1 -3 -/ lgoition Ilifig: 1 Elegem BT(
Site Ratiog: std ilorstpower @ 44o RPM
Si/ Cooditions: Ila feet Altitude @ Ha Degrets Fahrenheit
Spred Rige: 164 440 RPM

Fuel Type: IIATURAL GAS
ADJUSTMENT AND SETTINGS
Shutdowu Settiogof Overspetd Switch: na RPH
TESTING SPECIFICATIONS
Test per Engiatering Standard(s): ES 4018
Winess Test: Tes ti( llo (ertifitd Test Report: Tes xx
OTHER SPECIFICATIONS
Starter Motor Type: Tdi 110 pressure
6oreruor Type: A)ax Mechanical
lssued by: Wenn Mdatosii
late bid:
Chtcled by:
Date Checked: 27 5/0C)
cc Ralph fox Bruce Chrisman David Oye

Pete Platt Gerry Boner
Tina Harker Brenda Thornberry
filenn McIntosh Manuals
falIldo.niki 1/7/9
DPC 600/800
Integral Engine -Compresor
Instruction
Manual
Cooper Comeron Corp s Cooper-Bessomor Reciprocating Products Dhétston ■ AjC1X-Superior0peratIons
OPERATION AND MAINTENANCE
MANUAL
FOR AJAR DPC-600 4 DPC-000

HORIZONTAL GAS HNGINZ-CONPRE33OR3
rol 11211321111 1110 . 07 P01111111 COINIPMUL•011 111o. 07 03111111~1011
10113 111 411,00111 CTLIM/I 111011:111 CYL 1110111ii
DPC-600 15 x 16 3 11 2
DPC-800 15 x 16 4 11 3
pparAcz
The Ajax gas engine-compressor is cedures to be followed and precautions

designed specifically to meet the to be taken to achieve maximum
rigorous service requirements of performance from the Ajax engine-
continuous heavy duty operation. compreSsor. A complete review of the
Although built to tolerate the manual is reccmmended for those respon-
demands of this service, reasonable sible for the operation of the unit.
and intelligent cara during Installation instructions should be
installation and operation will add studied before setting the engine at
years to its life and keep its location. The trouble shooting
maintenance costs to an absolute guide section will be helpful in cor-
minimum. recting any operating problem which may
This manual outlines the pro- arise.
PARTS ORDZRING IMFORMATION
When ordering replacement parts parts.

for the Ajax engine-compressor, it
is important that sufficient iden-
tifying information be given to in-
sure that the correct part will be
supplied. Always include:
Part Number
Correct Description (from
Parts List)
size and Model of Unit
Serial Number of Unit
Contract Number of Unit
An illustrated parts list is pro-

vided with each unit, which lists
part numbers for all parts and
principal accessories. This list
also shows the correct description
or narre of the part which should be
used in ordering.
The Size, Model, Serial Number and
Contract Number of the unit should
be recorded from the nameplate for
convenient reference when ordering
Cooper Energy Services
Ti',.*
ocal Action ()son FAX Numbors: Mt. vemcn (Rotatrig) 514-392-7345
Field Problem Report MI. ~ion (En-Tronce) 614-393-8136
GrQvi_CitY (ReCiol 412-458-3652
Spengfieid (Alax-Supenor) 513-327-4388
(Retaiárw144-51-524-6557
1 Initiator: Location: Phone: Branch:
Customer and Contacta Location: Phone: Date:

i
Equipment Typo: l MO/SN: SO:
2 Description Of Concern/Nonconforrnance:
CES Part No. DrawIng Number: ., Rey #:
Part Description:
3 Date Response Required By:
4 Suspected Cause of Fh-oblern and Rocornmended Remedia' Correctivo Action

(Any Input Is Encouraged):
5 Supplier: Telephone: FAX:
CES P.O. No. Vendor Part No.
Part Description
Vendor Contad Name: Tftle:
FIVO-PC 9A4
CONTZNTS
SECTION PAGE SECTION PAGE
1 SATZTY 1 6 COOLING SYSTEM

(wwr''ENGINE CYLINDER COOLING 32
2 instar AND APPLICATION COMPRESSOR CYLINDER COOLING .... 32
BASIC DESIGN 5 PRECAUTIONS 32
SERVICING COOLER FAN 32
PRINCIPLE OF ENGINE OPERATION 6 SHAFT HEARINGS 32
ENGINE-COMPRESSOR APPLICATION 6
CRANKCASE ASSEMBLY
3 GENERAL DATA CRANKSHAFT BEARINGS 32
BASIC SPECIFICATIONS 8 CROSSHEADS ' 32
CROSSHEAD PIN BEARINGS 33
FUEL SYSTEM 8 LAYSHAFT DRIVE 33
EXHAUST SYSTEM 9 LAYSHAFT ROTARY OIL SEALS 33
CLEARANCES 10 POWER mamut ASSEMBLY
TORQUE TABLE 14 CYLINDER WEAR 34
AIR CHECK VALVES 34
SPECIAL TOOLS 15 ENGINE PISTON AND RINGS 34
4 INSTALLATION ENGINE PISTON ROD
STUFFING BOX 35
INSTALLATION DESIGN 16 COMPRESSOR PISTON ROD
FOUNDATION 16 STUFFING BOX 36
SETTING THE ENGINE-COMPRESSOR 17 ACCESSORIZS
GROUTING 18 SPARK PLUGS 36
AIR INTAKE FILTER 36
FABRICATED PIPING ASSEMBLY 19 BREATHER CAP 36
FLYWHEEL INSTALLATION 19 GOVERNOR 37
ALTRONIC IGNITION 37
FIELD CONNECTIONS 25 GAS INJECTION 42
FUEL GAS PIPING 25 INSTRUMENT PANEL 50
AIR AND GAS STARTING 25 SAFETY DEVICES 50
EXHAUST SYSTEM 25
5 ZNGINE-COMPRESSOR START-UP COMPRESSOR CYLINDER ASSEMBLY
PERFORMANCE 51
PRE-START-UP SERVICING 26 CLEARANCE ADJUSTMENT 52
COMPRESSOR CYLINDER PRE-START-UP 26 PERFORMANCE CURVES 52
SINGLE ACTING OPERATION 52
START-UP PROCEDURE 27 HYDROGEN SULFIDE GAS 52
6 MAINTZNANCZ COMPRESSOR
CYLINDER MAINTENANCE 53
LUBRICATING SYSTEMS COMPRESSOR CYLINDER BODIES 53
CRANKCASE LUBRICATION 28 COMPRESSOR CYLINDER LINERS 53
FORCE FEED LUBRICATOR 28 COMPRESSOR PISTOLAS 53
CENTRALIZED LUBE SYSTEM 29 COMPRESSOR PISTON RINGS 54
POWER CYLINDER LUBRICATION 29 COMPRESSOR PISTON RODS 54
POWER END COMPRESSOR PRESSURE PACKING 54
LUBE OIL SPECIFICATIONS 30 COMPRESSOR VALVES 55
COMPRESSOR COMPRESSOR TORQUE VALUES 55
CYLINDER LUBRICATION 31 COMPRESSOR LUBRICATION
(See Compressor Cylinder
Assembly Section)
SZCTION 2
DESIGN AND APPLICATION
BASIC DZSIGN
The heavy duty cast iron bed is lubricated through a pressurized system. A
mounted on a sturdy structural steel manual pre-lube system provides lubrica-
skid. tion to the main bearings prior to start-
The integral one-piece forged steel up.
crankshaft has both engine crank throws All piston rods pass through stuffing
and compressor throws. boxes, so the crankcase is isolated from
Main bearings are precision sleeve- the power and compressor cylinders.
type bronze bearings. A fuel injection system injects the
The forged steel connecting rods fuel into the power cylinders.
have precision bronze bearings in both Altronic capacitor discharge salid
ends. state ignition is standard equipment.
Heavy duty iron crossheads and steel The power end cooling system utilizes a
piston rods complete the drive train. unitized fin tube cooler, with the coolant
The engine pistons are made of cast being circulated by a centrifugal water
iron, while the compressor pistons may pump.
be either iron or aluminum, depending To identify various components of the
on the balancing requirements. compressor, reference is made to the fly-
The power cylinders which are of wheel side and cooler side of the unit.
ported two cycle design, are made of When standing at the power cylinder end,
high grade cast iron and have chrome the cooler side of the unit is to the left
plated bares. while the flywheel sida is to the right.
The compressor cylinders may be The power and compressor cylinders are
either iron or steel, depending on the numbered, starting at the flywheel side of
pressure requirements of the the unit.
application. When viewed from the flywheel side, the
Lubrication of the crankshaft and crankshaft rotation is clockwise.
layshaft assemblies is accomplished Figures 1-1 and 1-2 show outline views
with a combination of splash and flood typical of the Ajax engine-compressor
lubrication, while the cylinders are unit.
CCUMNI1101
Q3 3
'Qx g
".r•mta.
Figure 1.1 Figure 1.2
Top View DPC-500 Operating Sid• View
5
in the scavenging chamber aboye
atmospheric pressure. When the intake
ports are opened in the cylinder, the
slightly compressed air transfers to
the combustion chamber.
Figures 1-3 and 1-4 illustrate the
two-cycle principie which provides one
power stroke for each revolution of the
crankshaft, or one power stroke for
each two strokes (compression and
power) of the piston. Figure 1-5 shows ........ EXI4AvS7
the scavenging process which takes Figure 1.5 Scaversging coNNEcrow
place while exhaust and intake ports
are uncovered at the conclusion of the
power stroke.
7
AIR INTAKE SYSTEM
DPC-600 DPC-800
Air Flow, Cubic Feet Per Minute 3000 4000
Pressure Drop, Inches of Water 1 1
EXHAUST SYSTEM
DPC-600 DPC-800
Exhaust Pipe Size 10" - 15041 10" - 15041
Number of Exhaust Pipes 3 2
Length of Each Exhaust Pipe, Feet 6400 / RPM 6400 / RPM
(From Power Cylinder to Muffler, Flange-to-Flange)
Exhaust Temperature Switch, Shut-Down (Max) 850° F 850° F
MUFFLERS SPECIFICATIONS
DPC-600 DPC-800
Inlet Connections (3)10" 15041 (*)10" 150*
Outlet Connection, One (1) 18" 15041 18" 150*
Flow Through Muffler, Lbs. per Minute 160 210
Maximum Back Pressure, Inches of Water 5 5
Design Temperature 800° F 800° F
* 2 or 4, Depending on Configuration
9
CYLINDER SORE
NEW 14997"-15.001"
WEAR LiMIT +.01r
TORWE70FT.LBS.
600 FT LBS.
TOROLE 25 FT. LBS.
POWER CYLINDER GROUP
Cylinder Sore 14.977-15.001

wear Limit. 15.009-15.013
'Do not wear through chrome plating in bore
Exhaust Flange Size 10" 150*
11
TOROUE 3200 FT. Le& CLEARANCE
,
r .1 CROSSHEAO TO GU1PE
!O CCLID C43"- 017
HOT 00/3"- .015
CLEARANCE
8EARING TO CRANKPIN
0042"- 0066-
CLEARANCE
PN 7'0 9USHING
0035- 0055"
CO - 550.4
COMPRESSOR CROSSHEAD
AND CONNECTING ROD GROUP
Crankshaft Crankpin Diameter 7.499-7.500

Crankpin Bearing Inside Diameter Assembled 7.503-7.505
Crosshead Pin Diameter 4.499-4.500
Crosshead Pin Bushing Inside Diameter Assembled 4.503-4.505
Crosshead Diameter 11.984-11.986
13
SPECIAL TOOLS
Special tools have been developed to Thimble prevents damage to the packing
aid in performing some specific rings by the sharp edges of the threads.
maintenance tasks on Ajax compressors. When removing the pistan and rod, the
One such tool is the Pistan Rod threads must be wrapped with tape to
Thimble, which covers the piston rod protect the packing rings. The following
threads while they are passing thru the list gives the part number for this
packing rings during assembly of the thimble, as well as other special tools
piston and rod into the cylinder. This which are also available.
Description Part Deacriptioa Part ~bar

~ober 3/16" Hex Wrench BM-2122
Piston Rod Thimble T-939-D (For 3/8" Socket Set Screw) •
Pisten Rod Nut Wrench A-2921 1/4" Hex Wrench BM-2123
(For 1/2" Socket Set Screw)
Spark Plug Socket 1/2"(Std)BM-12027-1
(Shielded) BM-12027-2 1-5/8" Wrench BM-11811-B
(For Cylinder to Bed Stud Nuts)
(Integral) BM-12027-3
Extension Bar, 36" Long BM-11814
Spanner Wrench BM-11655 (For Cylinder to Bed Stud Nuts)
(For Gas Injection Valve)
1-1/2" Socket, 12 Pt. BM-11833
1/8" Hex Wrench BM-10700 (For Conn Rod Bolts)
(For 1/4" Socket Set Screw)
DPC-800 LOCA RING TOOLS
Socket, Flywheel Inst. BM-11878-A-1 Socket, Sheave Inst. BM-11878-A-5

Hex Wrench, Flywheel Inst. BM-11878-A-2 Hex Wrench, Sheave Inst. BM-11878-A-6
Hex Wrench, Flywheel Inst. BM-11878-A-3 Hex Wrench, Sheave Inst. BM-11878-A-7
Pull-out Bolt, Flywheel BM-11878-A-4 Pull-out Bolt, Sheave BM-11878-A-8
COMYRZSSOR ROD manaws
Rod Size Power Compressor
1-3/4" T-634-D T-634-E
2" T-935-A ----

2-1/4" ---- T-939-E
2-1/2" T-939-D T-939-D
15
FIGURE 4-1
Engine-Comprimor Typical Installatiott
SZTTING TEZ ZNOINZ-COMPRZSSOR damaged concrete. If he has omitted

this operation, remove from the areas
The engine-compressor mounted on where the grout must bond enough of the
its skid is normally set directly on surface of the foundation to lay bare
the foundation block with the primary uncontaminated, homogenous concrete.
precaution being certain that the unit Set leveling plates in level
is set level, accurately aligned with position on the foundation under the
the cooler, aligned with any other off- leveling screw locations.
skid accessories where applicable, and
adequately supported so that all PAZPARATION or aAsz AND TOOLS
bearing surfaces on the bottom of the
skid have full contact to avoid Clean paint, oil, grease and dirt
deflections in the bed or skid. from all surfaces which will come into
In setting the engine-compressor on contact with grout. For final cleaning
the foundation, it is necéssary to operation, use grout manufacturer's
place foundation bolts in the foun- recommended solvent using clean solu-
dation, either by pouring the foun- tion and clean cloth for last wash.
dation with bolts in place, or by sul- Lacquer thinner may be substituted if
phuring in the bolts after the foun- necessary; however, mineral spirits
dation has been poured. The location cannot be used for this purpose.
and sizes of the foundation bolts are Note: Grout may adhere to leveling
shown on the appropriate foundation screws, tools, forms or other items
drawing. The bolts must extend aboye which have not been protected with
the foundation to insure full thread paste type wax.
engagement in the nuts, taking into
account the space required for ade-
quate grouting. To allow for adjustment
in the location of the bolts if placed
before the block is poured, a common
practice is to center the bolt inside a
piece of 2" or 2-1/2" pipe, positioned
so that the top of the pipe is flush
with the top of the completed foun-
dation. The ends of the pipe should be
closed to keep out the foundation con-
crete. Foundation bolts may be tied to
reinforcing rods, but they should not
be welded in place.
After the foundation has thoroughly
set, as required by its size, climatic
conditions and the concrete mixture
used, the engine-compressor and cooler
can be placed on the foundation.
PRZPARATION or FOUNDATION
The foundation contractor should

have prepared the areas which will be
covered by grout by chipping from these
areas all laitance and oil-soaked or
17
FABRICATED PIPING ASSVIBLT The large end of the tapered key, which
is tapped with 1/2"-13NC threads to
Ajax engine-compressor units are facilitate removal, is installed to the
sold as completely packaged units, outside of the flywheel.
including all water piping and all gas Installation of the flywheel on the
piping between the unit suction flange crankshaft is not difficult; however,
and final discharge flange. Piping is the correct procedure must be followed
prefabricated at the shop and shipped to prevent splitting the hub when wedg-
to the job site for installation. By ing for installation. The appropriate
following the piping layout furnished flywheel wedge is included in the box
with the unit, it is a routine job to of parts shipped with the unit.
connect the prefabricated lines. The following steps must be care-
The flange connections on fabricated fully followed when installing the
gas lines are numbered to facilitate flywheel:
correct assembly. The contract number (1)Clean any paint out of slot in
is also stamped on the flange to aid in wheel. Insert the wedge as shown in
matching the piping to the unit. Figure 4-2, and drive into the slot
Air cleaners must be installed on using a ten-pound sledge. Be sure
the unit at the compressor job site. the wedge enters the slot squarely,
Exhaust piping, and gas or air starting and drive only deep enough to open
piping sometimes are not supplied by the hub bore sufficiently to slip
Ajax and are often fabricated in the over the shaft. Wedge should be
field to suit the specific job location driven in from side of flywheel
requirements. The cooling system must marked "This Side Out" to facil-
be filled with coolant and the itate removal of wedge after as-
lubricating system filled as required sembly. The wedge can most easily
with suitable lubricants as specified be driven when the flywheel is be-
here-after. ing held in an upright position and
resting on a solid surface.
FLYWEZZL INSTALLATION G Rfl. VAL (2)Check end of crankshaft and bore in
flywheel. File burrs, if necessary,
The flywheel must be installed at from bore and shaft.
location on all engine-compressor (3)To install flywheel, slide it on
units. This is due to the size and shaft by rotating back and forth
weight of the flywheel, which would and pushing manually until the end
create excessive handling problems if of the shaft is flush with hub
mounted before shipment. face. Do not sledge or attempt to
drive flywheel onto shaft with any
(DPC-600 FLYWHEEL] other device. If it has been wedged
properly,no difficulty should be
The flywheel is cast with a split encountered in sliding wheel into
hub having a straight bore which is
place.
machined to have a slight interferente
fit on the straight crankshaft exten-
sion. This split hub is opened slightly
by a wedge to facilitate mounting on
the crankshaft extension. A straight
keyway on the shaft matches a tapered
keyway in the flywheel hub to accept a
tapered key which is installed after
the flywheel is in place on the shaft.
This tapered key design contributes to
a more secure mounting of the flywheel.
The split hub is secured to the shaft
atter positioning by tightening a bolt
through the split in the hub.
At final factory assembly of all
Ajax engine-compressors, the tapered
key is custom fitted to the crankshaft
and flywheel to assure accurate align-
ment and positioning of the flywheel
and key. The serial number of the unit
is then stamped on the flywheel,
crankshaft end, and the tapered face
of the key, so that these custom
fitted parts will remain with the unit.
19
[DPC-800 FLYWHEELI CAUTION:
DPC-800 Compressor flywheels are Disconnect *park pluq vires or
installed with a ringfeder locking remove spark plugs wh•n rotating
device which is inserted in the bore of the crankshaft.
the flywheel and locks the wheel to the
crankshaft. The special procedures (6)If run-out exceeds the maximum
which must be followed for installation allowed, loosen all socket head
and removal are as follows: screws and cap flywheel into
position using a soft hammer on
rNSTALLATION wood block. Retighten screws
following same sequence as before,
(1)Clean the flywheel bares and mating and check that run-out is within
diameter on the crankshaft. tolerance.
Surfaces must be dry and free of
any burrs, rust or lubricants. R1:21DVAL
(2)Position the crankshaft so that the Using a 14mm hex wrench, gradually
$1 power piston is at top dead loosen the ringfeder socket screws
center. Using nylon straps lift the in several stages, following the
flywheel into position. The scribed tightening sequence shown in
timing fines on the face of the Figure 2, until all screws are
flywheel must be horizontal, with loose.
the line on the rim towards the
If the ringfeder does not slide
power cylinder. (See Figure 4.)
easily out of the counterbore,
Slide the flywheel on until it is
proceed as follows:
flush with the end of the
crankshaft. The outer taper ring can be
loosened by removing the three
Clearance Between ring gear and end
cadmium placed screws, which will
of starter pinion should be 1/16"
expose 20mm threads. Screw the bolt
minimum to 3/16" maximum. (See
of the slide hammer into one of the
Figure 1.)
20mm holes and bump to loosen.
(3)Check that the ringfeder is clean
Repeat Chis in all three 20mm holes
and dry -n inner and outer surfaces
and that the pilot bushings are in alternately, until the outer ring
is loose.
place under the three cadmium
placed screws. No oil or any dry The inner taper ring can be
lubricant is to be used on the loosened by tapping on the
locking surfaces. Lightly oil the remaining so-cket screws (which were
threads and under the heads of the loosened previously) using a soft
socket head screws. hamml.r. Tap lightly and evenly
(4)Install the ringfeder, making sure around the ringfeder bolt circle.
it is fully seated and square in
the bore. The three pilot bushings
are to be equally spaced. Tighten
all the socket head screws in three
successive stages (70 ft. lbs., 140
ft. lbs., 215 ft. lbs. torque).
The tightening sequence shown in
Figure 2 must be followed for all
three stages.
This sequence also applies to the
three cadmium placed screws.
Allow assembly to set for 30

minutes, Chen recheck all screws at
215 ft. lbs. torque, following the
tightening sequence in Figure 2.
(5)Atter final tightening of screws,
check flywheel run-out at rim and
0.D. See Figure 3 for maximum
allowable run-out.
21
DPC -800 SHEAV! TD-1323
9-15-86
INSTRUCTIONS FOR INSTALLATION AND RZMOVAL
DPC-800 Compressor sheaves are installed with a ringfeder locking device,
which is inserted in the bore of the sheave and locks the sheave to the
crankshaft. The special procedures which must be followed for installation and
removal are as follows:
rNSTALLAT/ON
A. Clean the sheave bares and mating diameter on the crankshaft. Surfaces
must be dry and free of any burrs, rust or lubricants.
B. Using a std. 1/2'-13 NC eyebolt, lift the sheave into position. Slide the
sheave on until it is up against the shoulder on the crankshaft.
C. check that the ringfeder is c1ean and dry on inner and outer surfaces. No
oil or any dry lubricant is to be used on the locking surfaces. Lightly
oil the threads and under the heads of the socket head screws.
DO NOT USE MOLYKOTE.
D. Install the ringfeder making sure it is fully seated and square in the
bore. Tighten all the socket head screws in three successive stages (30
ft. lbs., 60 ft. lbs, 90 ft. lbs. torque).
The tightening sequence shown in Figure 1 must be followed for all three
stages.
This sequence also applies to the three cadmium plated screws.
Allow assembly to set for 30 minutes, then recheck all screws at 90 ft.
lbs. torque, following the tightening sequence in Figure 1.
E. After final tightening of screws, check sheave run-out at rim and O.D.
See Figure 2 for maximum allowable run-out.
CAUTION:
Disconnect spark pluq vires and/or remove spark plugs when rotating the
crankshaft.
F. If run-out exceeds the maximum allowed, loasen all socket head screws and
tap sheave into position using a soft hammer on wood block. Retighten
screws following same sequence as before, and check that run-out is
within tolerance.
REMOVAL
Using a lOmm hex wrench, gradually loasen the ringfeder socket screws in
several stages, following the tightening sequence shown in Figure 1 until all
screws are loase.
If the ringfeder does not slide easily out of the counterbore, proceed as
follows:
The outer taper ring can be loosened by removing the three cadmium plated
screws, which will expose 16mm threads. Screw the bolt of a slide hammer into
one of the 16mm hales and bump to loasen. Repeat this in all three 16mm hales
alternately until the outer ring is loose. If a snde hammer is not avail-
able, use the 16mm pulí bolts supplied with the unit.
The inner taper ring can be loosened by tapping on the remaining socket screws
(which were loosened previously) using a soft hammer. Tap lightly and evenly
around the ringfeder bolt circle.
23
FIELD COMMOTIONS
FUEL GAS PIPING EXHAUST SYSTEM
Every engine-compressor unit is sup- EXHAUST PIPE AND MUFFLERS
plied with fuel gas piping.
A pressure regulator is included to Because of the port scavenging
reduce fuel gas of 260 PSI maximum in- design of Ajax engines, the design and
let pressure to that required at the installation of the exhaust system is
inlet of the engine, as follows: critical to satisfactory performance of
DPC-600 8-15 PSI the engine-compressor. Recommendations
DPC-800 8-20 PSI as to size and length of the exhaust
If the fuel supply pressure is pipe and the size and type muffler used
greater than 260 PSI, an additional must be strictly followed.
pressure regulator will be necessary to The full length of the exhaust pipe
reduce the fuel supply pressure below must be the same pipe size as the
260 PSI. flange on the gxhaust manifold.
Fuel gas connection sizes and Use as few elbows as possible, pre-
pressure regulator specifications for ferably no more than two, and always
fuel systems are shown in Section 2, use long radius elbows.
under "Fuel System'. The recommended Mufflers should be installed at the
sizing and hook-up should be strictly end of the recommended length of
followed as any deviation from these exhaust pipe.
standards can greatly impair engine Exhaust pipe length is stated as a
performance. Particular attention function of engine speed. The formula
should be given to orifice sizing and to determine the length of each exhaust
spring selection in the regulator to pipe, in feet, is: 6400 divided by RPM.
insure maintenance of correct fuel Therefore, at 400 RPM, the correct
pressure to the engine. length would be 6400 divided by 400
An automatic shutoff valve is used which equa's 16 feet.
to close off the fuel gas supply to the Maximur anticipated speed should be
unit in event of an emergency shutdown. used to determine this length.
This fuel valve should be located Be- Sizes of mufflers and exhaust pipes
tween the fuel regulator and the are listed in Section 3, under "Exhaust
throttle valve. Systems".
AIR OR GAS STARTING SYSTEM EXHAUST TEMPERATURE
A gas starting motor is standard on The exhaust gas temperature will
all DPC-600 and DPC-800 engine- vary with the load the engine-compres-
compressors. This permits the use of sor is carrying. Therefore, each
air or gas at approximately 125 to 150 power cylinder will be developing ap-
PSI for the vane type starters or 90 proximately the same power when exhaust
PSI for the turbine type starters. tempgratures are maintained at the same
The starting motor is equipped with level.
a starter drive, which engages with a A thermocouple is installed in the
gear on the flywheel to start the unit. exhaust manifold for each power cylin-
If an adequate supply of field gas der to sense the exhaust temperature.
is available no volume tank should be These thermocouples provide the signals
required at the unit for starting to the combination gauge and shutdown
purposes. If field gas pressure is switches located in the control panel.
greater than 150 PSI for vane type The switch-gauge shutdown tem-
starters or 90 PSI for turbine starters perature can be adjusted by turning the
a regulator must be used to reduce the adjustment screw on the front of the
pressure. switch while depressing the setpoint
When air is used for starting, a button. The setpoint should initially
volume tank or air receiver should be be set for the maximum temperature of
installed near the unit to provide suf- 850° F. Then, atter start up and oper-
Eicient air at the required starting ating conditions have stabilized, re-
pressure. Pressure can be maintained in duce the setpoint to approximately 10%
this tank either by a compressor mount- aboye normal operating temperature.
ed on the tank or on a service vehicle.
25
(10)Replace suction valves, cages, and wheel reaches a cranking speed of 50
covers on the first stage cyl- rpm, open the fuel gas valve to admit
inder. Just before replacing the fuel into the system. As soon as power
valve covers, insure each valve is cylinders begin to fire, close the
installed properly by moving the valve in the Starting Motor supply
suction valve plate back and forth line.
with a screw driver. Adjust Governor knob, as required,
(11) Repeat steps 2 through 11 for the to regulate Operating speed of the
second stage cylinder and succeed- engine-compressor.
ing stages. After engine is running:
(12) By manually operating lubricator
pumps, remove all air from the Check panel shut-downs.
lubrication tubing lines and pre- Check lubricator feeds, and adjust
lube the piston rod packing and iE necessary.
cylinder bore of each cylinder. Idle engine for 30 minutes be-
(13) Check cooler drive belts for fere applying load.
tightness.
As engine warms up, tighten
(14) Adjust variable volume pocket to
full open (outward) position. fasteners.
Apply thread lubricant to Check cooling water system for
adjusting thread. Consult unit circulation.
performance curve and make Listen to machine to detect any
clearance adjustments to irregularities which may be pres-
compressor cylinders based on ent.
existing operating conditions. Use Ajax compressor Start-up re-
(15) Pressurize compressor cylinders port and check all items listed.
and check for leaks. Replace or
tighten as required to stop
leaks.
(16) Open blow down valve and purge
compressor cylinders and piping to
remove all air.
(17) Position line valves according to
furnished start-up arrangement.
(18) Compressor cylinders are now ready
for start-up.
PRELUBE MAIN BEARINGS
Just before starting the unit, the

main bearings should be pre-lubed by
pumping the hand pump fifty (50)
strokes. This will flood the main bear-
ings with oil and provide initial lub-
rication. Anytime the unit is shut-down
for more than one hour, the main bear-
ings should be pre-lubed before start-
up.
START-UP PROCZDURZ
After all pre-start-up servicing has
been completed, it is recommended that
the flywheel be rotated manually
through one complete revolution to in-
sure freedom of movement of internal
parts.
Warning:
Be sure ignition ground switch is in
the "off" position during manual
rotation of flywheel.
AIR GAS STARTING
open the valve in the starting motor
supply line to admit pressure to crank
the Starting Motor. As soon as the fly-
27
The lubricator drain should be checked Points. These proportions can be
regularly for condensate. changed by replacing one or more
Periodic cleaning of the reservoir, sections of the divider valva.
with clean solvent, is recommended. Before connecting the oil fines to
Most lubricators used on Ajax the cylinder, operate the lubricator by
engine-compressors are equipped with means of the hand flushing units to
visible sight chambers, which instantly fill and fluah the fines, also to dem-
disclose the exact amount of lubricant onstrate that the pump units are oper-
flowing from the drip tuba to the lub- ativa and that the check valves are in
ricant well. This makes it possible to good order.
accurately gauge the amount of lubri-
cant being forced under pressure into Caution:
the system. Check operation of all lubricator pumps
A low oil level shutdown and float periodically, as failure of one or more
control is provided as standard equip- pumps in a manifold system could result
ment on lubricators. in a reduction of total flote so that
This float control can be piped to serious damage could result from
a reservoir to automatically replenish insufficient lubrication.
the lubricator oil supply as it is POWER CYLINDER LUBRICATION
used. The shutdown switch is wired to
the fuel valva to shut the compressor The amount and type of lubrication
down if the oil level in the lubricator required to provide safe and ample cyl-
drops too low. inder lubrication is based on years of
The lubricator reservoir should be Operating experience. A number of vari-
cleaned and flushed whenever changing ables, such as the gas being used as
the oil in the engine crankcase. fuel, have a great bearing on both the
quantity and the characteristics of the
CENTRALIZED LUBRICATION SYSTEM lubricating oil best suited. As a
Lubricating oil is distributed to guide, normal lubricator oil
lube points on the power and compressor consumption is eight pints per cylinder
cylinders through a centralized lubri- per day. In most cases, this
cation system. The lubricator pumps consumption will be the maximum amount
discharge oil into a manifold. This oil required. These rates can frequently be
flows through a tuba line to a divider cut back and still maintain adequate
valve unit, where it is distributed to lubrication.
the various lube points. Over lubrication is not only costly
Some units are also equipped with an from the standpoint of quantity of oil
optional lube panel, which includes a consumad, but also it is the greatest
filter, flow meter and No-flow switch, single cause of carbon build up.
ahead of the divider valve. Inasmuch as the number of drops of oil
Filter - A 25 Micron filter prevents in one pint is so dependent upon such
impurities in the oil from entering things as temperature and viscosity of
the system. oil, the amount of oil used for
cylinder lubrication should always be
Flow Meter - The flow meter mechanic- based on the recommended pints per day
ally records and measures the total rather than the drops per minuta or
volume of oil being delivered to the stroke. Due to the poor reliability of
system. It aleo contains a pressure the force feed lubricators at very low
gauge which provides a constant rates, it is recommended that in no
check of system operating pressure. case should the lubricator feed rata be
No-Flow Switch - This switch reacts to reduced to less than two drops per.
no-flow conditions in the system. If stroke of the lubricator pump.
any condition occurs which prevents LUBRICATION OIL FOR POWER CYLINDERS AND
the flow of oil through the system, CRANKCASE
this switch closes and an electrical
signal (or pneumatic signal*) is Refer to ES-1006
transmitted to the Compressor LUBRICATING OIL FOR COMPRESSOR CYLINDER
Instrument Panel. AND PRESSURE PACKING
*Note - Some units are equipped with
Pneumatic No-Flow Switches. Refer to "Compressor Cylinder
Divider Valvas - The divider valves Maintenance" for lubricant specifi-
contain metering pistons which di- cations.
vide the flow of oil into pre-set
proportions for delivery to the Lube
29
Cooper Camerco Corporation 4•114•Assrher
Cooper-Sasesener Reciprocating Products Dividan Enginewing Standards
LUBRICATING OIL RECOMMENDATIONS

FOR AJAR ENGINES - COMPRESSORS
1.0 GENERAL
1.1 The lubrication of Ajax equipment requires the use of premium quality lubricating oda designad
specifically for natural gas 2-cycle engine - compressor service. This standard describes °á which
have proven successful in field use.
1.2 Customers operating engines with exhaust catalyst systems, fuels with high sulfur contenta, Iandfill
gas, unusual fuels or non-tradicional application should contact Ajax Engineering for lubricant and
rnaintenance recommendations.
1.3 Recommendations for compressor cylinders and piston rod packing are found in Engineering Standard
ES-1002.
2.0 QUALITY AND PERFORMANCE
2.1 Satisfactory oil quality is the responsibility of the refiner, blender or rebrander. Only reputabie
companies with proper service organi7ations should be usad as suppliers.
2.2 Cooper Energy Services does not guarantee the quality or performance of lubricating oda.
2.3 Cooper Energy Services does not endorse particular brands of oil. For customers convenience,
information on oda by brand name is maintained by Cooper Energy Services. Customers are invited
to advise Ajax Engineering or service representatives what brands of oils are preferred. Cooper
Energy Services can Men cite the oils which have given satisfactory service in similar application.
3.0 GENERAL SPECIFICATION:
3.1 A general description of oils suitable for use in Ajax equipment is an ashless oil spacifically formulated
for 2-cycle natural gas engines with the following properties:
3.2 Physical Properties:
Viscosity Index: 70 Minimum ASTM D2270
Flash Point: 400°F (204°C) Minimum ASTM D92
Pour Point: 10°F (-12°C) Maximum ASTM D97
3.3 Ash Level: Ashless oils with a sulfated ash content of up to 0.1% maximum by ASTM D 874 are
preferred. Oils with ash levels up to 0.8% may be usad, but they may cause combustion chamba
deposita, especially if they contain more iban 0.04% by weigbt zinc.
of
0 inetor
E .
Quality Controi
5~4~, Aja: Engin. SuP~,
Enei~
isound Does
5/1/116 ES 1006
/fp 1.-.....-dl.
~es Cimilivdm ~I A.11.C.E
.--CIP.4.— NIEW Nepe 1 of 3
si 5 11
,17 I— a347r/75'. "
.1iyirl'°- S,
30
Cooper Can»ron Corporation A4sx 4wersor
Coopw.Secasmer Reoiptocatine Products DIvision 6%0~1 ~ves
4.2.2.2 To properly warm the unit, find the overnight low ambient temperature in the first column
of chao below. Stars and idie the unit at 300 RPM for the number of minutito required
for the overnight low ambient temperature. Mien chut the unit down the number of
minutos required. Repeat this sequence the number of times Usted. Continue in this order
until you have met the requirements for that temperature rango. This procedure will allow
components such as the crossheads, pies, bushings and hearings sufficient time for
expansion to maintain proper running clearances.
Numbet of Times Minute* with

Overnight Low Ambient Minutos at !die Minutas Sequence to be Light Load %lote
Temperature (300 RPM) Down Done Fun Loading
90 to 70°F (32 to 21°C) 20 0 1 15
69 to 50°F (20 to 10 °C) 30 0 1 20
49 to 40°F (9 to 5°C) 45 0 1 20
5 5 3 No Load
39 to 32°F (4 to 0°C) —,
40 0 1 30
3 3 3 No Load
31 to 18°F (-1 to -7°C) 7 3 No Load
7 •
50 0 1 30
3 3 5 No Load
17 to 0°F1-8 to -17°C) 7 4 No Load
7
60 0 1 45
2 2 3 No Load
-1 to -20°F (-18 to -28°C) 5 4 No Load
5
r491,1 Rifar to Paragraphs 15 15 3 No Load
4.1 and 4.2.
30 30 1 No Load
60 0 1 45
F
Director Maneo«. 34.4~sor. AM Erqdrwo Supervisor, Cornpeesaor
Enginaanno Engi.Mi
Iseued by Dote
S/1/91 ES 1006
of E Quadit
/ • ~N Diorthorn u.« •,e,c,t
••
, _ „
,. ) x. NéV1/ P meg 3 le1 3
?" 11
sr",/rf 7"fir
30.2
3 IUBRICATING_ OIL FOR COMPRESSOR CYLINDERS AND EISTON ROD PRESSURE PACKINQ
For clean, dry gases such as natural gas, helium, hydrogen, and nitrogen
with outlet temperatures up to 350° F. (149°C), a high quality, solvent
refinad straight-mineral oil will usually provide satisfactory
lubrication. Crankcase oils specified in Point 112 are satisfactory.
Reciprocating compressors in air service are often troubled by hard carbon
deposits which interfere with discharge valva operation. Such a problem may
often be alleviated by use of so-called naphthenic or low viscosity-index
oils which tend to produce less carbon, and of a softer natura, than the
more paraffinic or high viscosity-index oils. For air compressor service in
which discharge temperatures exceed 300° F, but do not exceed 350° F, a
fire-resistant synthetic lubricant is recommended due to the fire hazard
preaent.
CADMIO/1: Synthetic lubricants must not be used without specific permission
from Ajax. All compressor cylinder non-metallic components must be reviewed
to make sure they are compatible with the specific brand of synthetic
lubricant.
Under certain conditions, where oil films may be washed or displaced from
lubricated surfaces, either by light hydrocarbon liquids or entrained
water, compounded oils (i.e., petroleum oils containing acidless animal,
vegetable, or synthetic fatty oils) are recommended. In most cases 3% to 5%
compounding should prove satisfactory.
The following table lista recommended oil viscosity for various cylinder
pressures:
CYLINDER PRESSURE - PSIQ VISCOSITY S.U.S.@ 210°F USCOSITY cST 9 98.9°C
0 - 1000 55 - 75 8.77 - 14.26
1000 - 1500 75 - 95 14.26 - 19.18
1500 - 2000 95 - 115 19.18 - 23.83
2000 - 3500 115 - 150 23.83 - 31.68
3500 & Up 150 Minimum 31.68 Minimum
Since it is virtually impossible for a compressor manufacturer to test all
of the available lubricants on today's market, with all of the various
gases and compressor applications encountered, this standard is offered as
a guide only.
It is suggested that each customer request a specific lubricant recommen-
dation, for his application, from the oil supplier of his choice. Of
course, if requested to do so, Ajax Engineering will work with the customer
and his lubricant supplier in a coordinated attempt to arrive at a suitable
lube oil recommendation.
31
at the top of each quid° atter the pis- rear plata. Extreme caro should be tak-
ton and connecting rod have been se- en in pressing in the oil seal to be
curely fastened in the crosshead. This
crossehad guide clearance is shown in
Section 3. Measure by using long feel- /1 ,
%.,'/// Su • 104 45. 11
011, Stal,
er gauges at the top and with crosshead
at various positions for the entire
length of the guide.
CROSSHEAD PIN BEARING
This bearing consists of a removable
bronze bushing which is shrunk into the
connecting rod. When this bearing
becomes excessively worn, it must be
replaced by a new bushing, which is
lined up and Torced into the rod, using
00 NOT 0'1,103 OM
a piece of wood or block of soft metal T.( S.* MG t0.40(0
as a cushion. Irtieet. WITAINIR
my' I S(ÍT RING)
The clearance between the bushing
and the crosshead pin is given in Sec-
tion 3.
The crosshead pin bearings are
locked in position in the connecting FIGURE 6-1
rod by means of a dog point set screw. Installation Sleeve
This prevents the bearing from working Layshaft Rotary Oil Sea'
loose in the connecting rod.
LAYSHAFT DRIVE
The layshaft drive gear on the certain that it is pressed in straight,
crankshaft has "O" stamped on two ad- making sure that no pressure is exerted
jacent teeth and the driien gear on the on the "O" ring retainer hub, until it
layshaft has "O" stamped on one tooth. bottoms in the control box rear plata
When re-assembling the engine atter counterbore. Figure 6-2 shows the oil
dismantling, be careful to mesh gears seal correctly positioned. After the
with the marked tooth on the layshaft oil seal is placed into the rear plata,
gear located between the two marked as described aboye, cara must be
teeth on the crankshaft gear. exercised when bolting the plata to the
control box to line up the roll drive
LAYSHAFT ROTARY OIL SEALS(DPC-600 only) pin in the seal to the keyway in the
Although there is seldom a need to layshaft, gear as shown in Figure 6-2.
replace the rotary type oil seal in the
control box rear plata, care must be
taken to assure proper installation in
those instances where such field re-
placement is necessary.
As indicated in Figure 6.1, a sleeve
should first be made to facilitate in-
stallation of the oil seal. This sleeve
should be made up with dimensions ap-
proximating a 3" 0.D., 2-3/8" I.D. and
1-1/2" length.
The sleeve should then be usad to
Press the oil seal into the control box
CONTROL BOX n'AAPLAT(
FIGURE 6-2
Layshaft Rotury Oil Scal Installed
33
faces the crankshaft. The smaller
diameter can be readily identified as
it is marked TOP. Improper installation
of these rings will materially increase
break-in time and shorten their life.
See Figure 6-5.
110 GAP LISTE0 IN

GAP sEcTiON 2.
FIGURE 8-4
Engine Piston Ring Tapered Face
Carel should be exercised in in-

stalling new rings to be certain that
the smaller diameter of the rings on
the cylinder head end of the pisten
face the cylinder head. on the skirt FIGURE 8.5
end of the pisten, the smaller diameter Enginis Piston Ring Installation
ZNGINZ PISTON ROD STUTTING BOX

The stuffing box seals off the nents carefully slid along the pisten
crankcase from the scavenging chamber, red to expose the packing rings. The
in which pressure and vacuum are alter- packing rings are made up of segments
nately developed. The stuffing box con- and can be disassembled by removing the
tains metallic packing, which prevents garter spring. The replacement ring can
products of combustion from entering then be installed by positioning the
the crankcase and contaminating the segments around the red and assembling
lubricating oil, and, at the same time, the garter spring to hold them in
prevents leakage of lubricating oil place.
from the crankcase to the scavenging In order for the stuffing box to
chamber. function properly, the packing rings
Before re-assembling the stuffing must be assembled correctly. The vacuum
box on the rods, carefully inspect the cup, which is next to the power cylin-
pisten red for any roughness, or nicks. der, contains two seal rings. Next is
Al). marks must be removed from the red the wiper cup, which contains a seal
with a fine stone. If the marks cannot ring and two grooved wiper rings. This
be removed, the piston and rod should is followed by a retainer plate and a
be replaced. baffle or scraper ring, which is con-
Use a thimble, which slips over the tained in the scraper cup.
pisten rod, when the rod is being in- All rings must be assembled on the
serted through the packing rings. This pisten rod with the lettered or
will protect the packing rings from the grooved side facing the crankcase. See
sharp edges of the threads. Thimbles Figure 6-6.
for pisten red installation are listed
under "Special Tools" in Section 3.
To remove the power end stuffing
box, the cylinder head and pisten and
rod assembly must be detached from the
bed. The stuffing box is removed
through the sida cover opening after
removing the pisten and red assembly
and cylinder head.
PACRING RING INSTALLATION

Replacement packing rings can be
installed without removing the cylinder
head and pisten and rod assembly. Atter
removing the side cover, the stuffing
box can be taken apart and the compo-
35
GOVERNOR forms thl energy to a voltage high
enough fire the spark plug.
Description: The p_sition of the magnets on the
The standard mechanical governor is flywheel establishes the basic ignition
a vertical flyball, centrifugal type, timing of the Altronic system. Since
self-lubricating, and gear driven from these magnets are installed in hales
the layshaft. The threads on the spin- drilled into the flywheel face at the
dle pump oil from an oil pocket on the factory, their positions are fixed.
governor body to the governor weight The bracket on which the pick-up
pins, sleeve and spindle bearings. coils are mounted is drilled so the
The governor spring adjusting knob pick-up coils can be installed in var-
is turned clockwise to increase speed ious positions. The pick-up coil is
of the engine; counterclockwise to factory installed to fire the spark
decrease speed. Speed changes are made plug at 9° before the pistan reaches
while the engine is running. top dead center. This is the recom-
The governor is connected to the mended setting for most installations.
throttle valve through the linkage to The ignition can be advanced 2
regulate the speed of the engine- degrees by installing the pick-up coil
compressor. one set of hales lower in the bracket,
and can be retarded 2 degrees by rais-
Nota: ing the pick-up coil one set of hales.
A hydraulic governor may be supplied The spark produced by the salid
in place of the standard mechanical state ignition is of very short dura-
governor. When this occurs, a separate tion and high intensity. This permits
instruction book for the hydraulic successful firing of plugs.with wider
governor is included in the composite gaps or partial fouling than would be
manual for that compressor. possible with magneto ignition, thus
giving a much longer spark plug lite.
ALTRONIC IGNITION - DPC-600

Altronic ignition is standard
equipment on all Ajax engine-
compressors. The Altronic ignition
system is a salid state capacitar
discharge ignition system consisting of
an alternator with electronic component
box, ignition coil, pick up coil
assembly and flywheel mounted timing
magnets.
The assembly of alternator and
component box is installed on the
control box and is driven by a gear on
the layshaft. The alternator is driven
at twice engine speed and generates
power which is stored in a capacitor
located in the component box. During
operation the magnets mounted on the
flywheel pass a pick up coil assembly
located near the inner face of the
flywheel and this induces a voltage
which is sufficient to trigger a solid
state switch. This switch raleases the
energy stored in the capacitor which is
then transmitted through wiring to the
ignition coil located on the engine
cylinder head. The ignition coil trans-
37
ALTRONIC III IGNITION SYST124 - DPC-800
INSTALLATION INSTRUCTIONS
The following parta are required for each installation:
1. Altronic III Unit
2. Wiring Harness
3. Ignition coils - 501 061, 501 061-S, or 591 007 - one per spark plug
4. Engine Drive Member (base mount) - 560 001
ENGINE
Set engine so that No. 1 cylinder is at the ignition firing point.
ROTATIOU
Determine the rotation of the Altronic III unit (looking at the drive end
of the Altronic unit) for the engine being equipped. Even firing interval
units can be usad for either CCW or CW rotation.
BASE-MOUNT UNIT
Attach 560 001 engine drive member to the end of the fiex coupling with two
spring pins, provided. Locate the timing mark on the housing for the proper
rotation (see below). Rotate the unit shaft until the red mark on the shaft
fines up with the proper mark on the housing. Install unit on engine
bracket. Slip engine drive member over hub; insert and tighten locking
screw and nut. Final timing should be checked using a timing light with the
engine at operating speed.
NOTE: For the safety of operating personnel, the engine manufacturer's
shield must be in place covering the flex coupling/engine drive.
FLANGE-MDUNT UNIT
Locate the timing mark on the housing for the proper rotation (see below).
Rotate the drive coupling until the red mark on the shaft fines up with the
proper mark ori the housing. Mount unit to engine, keeping the two red fines
together as close as possible. If the two fines cannot be made to meet by
rotating the entire unit, remove the four screws which fasten the back
cover assembly to the unit. The entire back cover assembly should then be
pulled away from the unit about Carefully tilt the top of the cover
away from the unit, keeping the internal plug (underside of circuit board)
connected. Rotate the distributor shaft until the two marks described aboye
line up. Then reinstall the cover to the unit, engaging the gears, and
keeping the two red marks together. Securely tighten the four fastening
screws. Final timing should be checked using a timing light with the engine
at operating speed.
CW ROTATION CCW ROTATION

= Al = 9-13 -
39
MURPHY SWITCHES OR PANEL
For proper operation of Murphy tattletale switches or fuel valve, use panel
adaptor 501 213, as shown below.
LEA() /O SEICI=041 »e=

at roa. MILVE
INSTALLATION-SHIELDED SYSTEM
PRIMARY
1) It is recommended that primary connections be made at a terminal strip.

2) With Altronic primary cables, loosen 1/2-14 NPT adaptor from conduit and
tighten in cylinder junction box to 8-10 ft. lbs.
a) With straight plug-in connector, plug into coil before retightening
conduit nut to 1/2-14 NPT adaptor.
b) With right-angle plug-in connector, adjust insert alignment to match
keyway in ignition coil connector by loosening connector assembly and
carefully rotating elbow without straining primary wires.
3) Hand tighten all primary connector nuts. Then carefully tighten 1/8 turn
with pliers - DO NOT OVER-TIGETEN.
SECONDARY
1) Spark plug threads and seat in engine head must be free from paint, dirt,
etc. to insure a gond electrical ground for the spark plug. Use a thread
and seat cleaner tool.
2) Spark plugs should be uniformly gapped to a setting depending on the appli-
cation (contact the engine manufacturer or Altronic). Be sure spark plug
insulator is clean; if not, clean with a clean, dry paper towel. Install
spark plugs to recommended torque value using a torque wrench. Do not use
thread lube.
3) Using a clean, dry paper towel, clean the porcelain end of the shielded
spark plug lead. Install the coil end of the shielded lead first and
tighten nut securely. Then install the spark plug end and tighten to 8-10
ft. lbs. Do not use thread lube.
4) With integral coils, screw coil on to spark plug hand tight. Then tighten
1/6 turn with wrench. Do not use thread lube. NOTE: The metal can of the
integral coil must be grounded. - DO NOT TEST COIL UNLESS CASE IS
GROUNDED.
41
OPERATING INSTRUCTIONS FOR PLUNGER TYPE, SPILL-PORT GAS INJECTION SYSTEMS
GENERAL DESCRIPTION
The basic operation of an engine rotary throttle valve, similar to those
equipped with gas injection is the same used in a standard low pressure fuel
as for low pressure fuel. The primary system, is actuated by the governor
difference between gas injection and through a control rod and varíes the
low pressure operation is that the fuel gas volume supplied to the injection
is injected directly into the cylinder valves to suit the engine load. The
in gas injection operation instead of injection valves, which are installed
being drawn into the engine with the in the power cylinder heads, inject the
air charge through the scavenging fuel gas directly into the combustion
chamber. The injection is timed to take chamber.
place just as the exhaust ports are A 1/4" tube line is used to transmit
closing on the compression stroke. the incoming fuel pressure from the up-
Therefore, the exhaust gases are scav- stream side of the throttle valve to
enged with air only, thus preventing the top of the fluid tank. If at all
fuel loss through the exhaust ports possible, this line should be taken
during scavenging. from the upstream side of any automatic
This system utilizes cam operated fuel shutoff valve in the system, but
mushroom plunger pumps which give a still be downstream of the fuel pres-
constant lift to hydraulically actuated sure regulator (with a check valve in
fuel injection valves. These pumps are line): This pressurizing line may be
located on top of the control box and closed off by means of an angle valve
are actuated by caros on the layshaft. A located at the tank end of the line.
s.
FLUID SUPPtY TANK
BY-PASS VALVE OPEN

FLUID
KRIAITS FLOW IN (SuCTIC*4)
FUEL
EITHCR DIRtCTION GAS
FLUID
UUCTMN)
7LLI0
(Pm:30W )
FLOW CONTROL VALVE

FLOW CONTROL VALVE SHOWN WITH
BY-PASS VALVE OPEN DE-ACTIVATING
THE INJECTION VALVE. •
UEL SNUT-OFF
VALVE
FLUID
(11/(3SuNE)
PLISAP
JUNCTION ROTARY
BLOCK THROTTLE
VALVE
1/4145 CADA IUP)
FUEI. GAS
LAYSHAFT
FLUID
(SucTION)
FLUM
( M'E SSURE )
INJECTION VALVE
(OPEN)
FIGURE 6-8
SPILL PORT GAS INJECTION SYSTEM
BLEEDER VALVE SH0wN WITH PLIMP IN THE INJECTION STROKE CO-437
42
A 3/8" tube line supplies fluid from OPERATION OF THE SYSTEM
the tank to the plunger pumps. Included As the plunger in the pump is lifted
in these lines are the flow control by the cam, the resulting pressure is
valves at the pumps which prevent re- transmitted to the plunger in the
turn flow to the tank on the pressure injection valve. This plunger contacts
stroke. the end of the injection valve stem so
A 1/4" tube line connects each pump that any motion of the plunger will
to the related injection valve and open the gas injection valve. When the
transmits the hydraulic pressure from injection valve spill ports open,
the pump to the plunger in the injec- relieving the pressure, the valve
tion valve. spring immediately forces the plunger
At the injection valve end of this up and closes the gas injection valve.
line is a bleed cock through which en- After the pump plunger has completed
trained air may be removed from the its lift and starts the return stroke,
system. it begins to create a slight vacuum in
A 1/4" tube line connects the in- the system which is relieved by the
jection valve to the fluid supply tank. opening of the flow control valve. Upon
This line returns to the supply tank opening, fluid flows from the tank to
the fluid which is vented when the the pump barrel. The fluid in the tank
spill ports in the injection valve are is pressurized with the fuel gas
uncovered. pressure.
The engine speed is controlled by a
rotary throttle valve which is actuated
by the governor.
FUEL
GAS
FLOW CONTROL VALVE
/ott:43...."‘ FLUIR (SUCTION)
PF'
FLUIO (SUCT)ON) CAN

(GOING DOWN)
UCL GAS
INJECTION VALVE
FIGURE 6-9
tCLOSED)
SPILL PORT GAS INJECTION SYSTEM
SHOWN WITH PUNP IN THE SUCTION STROKE
CD.43I
43
Hydraulic Fluid Gas Injection Timing Instructions
This system is designed for use with To ensure the correct gas injection
Ajax Hydraulic Fluid (YAE-2150-1). One timing, the gas injection cams on the
gallon of this fluid is furnished with layshaft must be indexed with respect
each system. Do not substitute any to the crankshaft. The correct timing
other fluid without prior approval of for the start of the hydraulic plunger
Ajax Engineering Department. lift is 2° ABDC.
The closed hydraulic system requires Checking the gas injection timing
only a small amount of make-up fluid; on the DPC-600 engine.
however, the operator should watch this 1) Positioning of the crankshaft,
fluid level carefully until he is fa- can be determined from the
miliar with the amount of make-up fluid flywheel keyway, which is
required. He should also be sure that oriented in the direction of the
the make-up fluid is clean, as dirt #1 power cylinder crankshaft
will damage the injection valve, injec- journal (see Fig. 1). In other
tion pump, and flow control valve, thus words, if the keyway is at the 9
causing the system to malfunction. o'clock position in Figure 1, the
Fluid Supply Tank #1 power cylinder is at TDC. Use
an adjustable square head with a
This is the standard fluid tank level vial, placed against the
equipped with a full height transparent outer fíat of the flywheel
plastic oil level gauge. Filled to the keyway. Rotate the crankshaft in
top of the oil level gauge, the tank the direction shown. The correct
holds one quart. The top is sealed with crankshaft position for checking
a 1-1/4" pipe plug. the gas injection cam timing is
Pump Assembly 13° ABDC (X=13°).
The pump assembly consists of a
plunger and barrel assembly, which is
operated by a hardened cam mounted on
the layshaft. The cam has a constant
lift of .270".
ROTATION FACING
FLYWHEEL ADJUSTABLE SOUARE
HEAD WITH LEVEL VIAL
POWER CYLINDERS HORIZONTAL

T.D.C. REF
DPC-600 CRANKSHAFT
FIGURE 1
44
2) Once the crankshaft has been hole on the *1 power cylinder cam.
positioned, remove the hydraulic This is the cam furthest from the
plunger and top cover from the crankshaft. The rod should be a 90°
accessory case. Opposite the set to the top surface of the accessory
screw on the cam hub is a 1/4" dia. case. This may be checked with a 90°
hole. Place a 1/4" dia. rod in this square, as shown in Figure 2.
90' SOUARE IFT

I/4" DIA. ROD
r
• -ACCESSORY CASE
1/4' DIA.
/,1
A
FLYWHEEL END ROTATTN

///-/Y/7/////// /
VIEW LOCKING
FROM FLYWHEEL
TOWARDS CONTROL BOX
FIGURE 2
Checking the gas injection timing position in Figure 3, the #1

for cylinder DPC-800 units. power cylinder is a TDC.
1) Positioning of the crankshaft can Place a straight edge on the
be determined from fines scribed crank end in line with the
in the Pace of the crank on the scribed fines. Hold an adjustable
flywheel end, which indicates the square head on this straight edge
position of the various and rotate the crankshaft in the
crankshaft journals (Fig.3). In direction shown. The correct
other words, if the scribed line crankshaft position for checking
with the *1 next to it is the gas timing is 2° ABDC (X-2°).
positioned at the 9 o'clock
45
ROTATION
FACING FLYWHEEL
ADJUSTABLE SOUARE
HEAD WITH LEVEL VIAL
POWER CYL1NDERS
11■1
-Á- HORIZONTAL
T.D.C. REF
X
----...,t
DPC-800 CRANKSHAFT
FIGURE 3
2) Once the crankshaft has been of the opening ramp, so that
positioned, remove the plunger checking the rod position on the #3
pumps and cover from the right bank results in the correct timing
bank of the accessory case (as for #1. Place a 1/4" dia. rod in
viewed from the flywheel looking this hole on the cam furthest from
towards the control box). Opposite the crank. Use a 90° square to
the set screw on the cam hub is a check the angle of the rod with
1/4" dia. hole. This 1/4" hole is respect to the accessory case as
positioned 90° after the beginning shown in Figure 4.
90'
90* SOUARE
/
FLYWHEEL END
*1 BANK 1/4' DIA. ROO
*3 BANK
ROTATION
1/4' DIA. VIEW LOOKING FROM FLYWHEEL
TOWARDS CONTROL BOX
FIGURE 4
46
Another check on gas cam timing is to in Figure 1 or 3. As soon as the dial
use a dial indicator on top of the indicator moves, stop and measure the
hydraulic plunger pump of the 111 power position of the crankshaft (Figure 1 or
cylinder, as shown in Figure 5. Rotate 3). The correct timing is 2° ABDC on
the crankshaft in the direction shown all standard units.
DIAL INDICATOR
(1/2' MIN. TRAVEL
REC OMMENDED)
FIGURE 5
The lay shaft drive gear, driven if these punch marks are missing, or
gear and driven gear keyway location the checking procedure does not come
are marked at the Ajax factory ,as out correctly, proceed as described in
indicated in Figure 6. This should Section 6.
insure the correct timing. However,
CRANKSHAFT MOÚNTED ---

DRIVE GEAR
MATCHMARK AT ASSEMBLY
LAYSHAFT MOUNTED
DRIVEN GEAR
FIGURE 6
47
With the drive gear and key taper is facing out. When the
installed on the crankshaft and the proper gear position has been
driven gear removed from the layshaft, determined, install the tapered
position the crankshaft as described. key and punch mark the gears and
Rotate the layshaft by hand so that the key location as shown in Figure
#1 cam is in the correct position, per 6. This will allow correct
paragraph 2 of each respective assembly should the unit have to
section. be serviced in the future.
1) Adjustment for setting the gas 2) EMPORTANT: When one or both of
injection timing is provided for these gears is replaced, be sure
by 4 keyways in the layshaft to check for proper backlash.
gear. Each of these keyways is This should be checked at 90°
oriented differently with respect intervals of the gears. Backlash
to the gear teeth. Slide the should be .003" to .006". If
layshaft gear completely onto the backlash is not within this
layshaft and check to see if the tolerance range, pull the dowel
keyway in the gear lines up wíth pins which locate the layshaft
the keyway in the layshaft. If bearing, and adjust the position
the keyways do not line up, of the layshaft bearing to obtain
remove the layshaft gear and proper backlash between the
rotate it about 90° and slide it gears. Then re-drili and dowel
back onto the layshaft. Do this the layshaft bearing to maintain
until the keyways line up. Please this setting. Remove the layshaft
note that the keyway in the drive gear and make sure the
layshaft gear is tapered to layshaft turns freely by hand.
accept a tapered key. The Re-install layshaft drive gear as
layshaft gear must be installed match-marked previously.
so that the large end of the
48
FLOW CONTROL VALVE
permit fuel gas to enter. This pressure
The flow control valve is mounted on on the fluid in the tank facilitates
the pump in the tube line supplying the bleeding off small entrained air
fluid from the tank to the pump. The bubbles.
flow control valve seals the pressure Caution:
during the delivery stroke of the pump
but permits replenishing of the oil The fluid level in the tank should
supply to the pump during the suction nevar be allowed to drop lower than
stroke. The flow control valve also the level of the return line» from the
contains a needle-bypass valve which is injection valvas to the tank.
used when bleeding air from the system. BLEEDING OF AIR BEFORE STARTING
Note: When starting the engine the first
The needle bypass valve must be time after the system is installed or
fully closed for gas injection oper- any time the fluid has been drained
ation. from the system, it is of utmost impor-
INJECTION VALVE ASSEMBLY tance that all air be bled from the
system as described aboye. If the sys-
The injection valve assembly has an tem has not been relieved of air bub-
adjustment collar which is used to vary bles, the injection vaives will not
the lift of the valve stem by changing open.
the location of the spill ports. The
valve is opened by hydraulic pressure THROTTLE VALVE
from the plunger pump and is closed by The throttle valve is of the
the spring as soon as the spill ports standard rotary type. It is linked to
open to relieve the hydraulic pressure. the governor by means of control rods
INJECTION VALVE LUBRICATION and ball joints. The linkage to the
governor lever should be adjusted so
The grease fitting on the side of that the engine will carry full load
the injection valve body is for lubri- with the throttle approximately one-
cation of the valve stem. third to one-half open.
Note: GAS PRESSURE
The injection valve should be
For best throttle regulation and
greased once a month with one shot of with the throttle about one-half open
Anti-Friction Compound Number 2. A tube
of this compound is supplied with each at normal full load, the gas pressure
gas injection system. Do not use any should be set as follows:
DPC-600 8 - 15 PSI, DPC-800 8 - 20
other compound without approval of Ajax
PSI. Normal operation will be near the
Engineering Department. high setting, but with rich gas, better
BLEEDER COCK operation will be ob-tained with a
The 1/8" brass cock mounted in the lower pressure setting.
pressure line on the injection valve CYLINDER LOAD BALANCE
head is used to bleed off entrained air The exhaust temperature is an
from the system before starting the en- indication of whether the power cylin-
gine. When bleeding off the entrained ders are equally loaded. If one cylin-
air, it is necessary to have the needle
der is doing more than its share of the
bypass valve in the full open position.
When using these bleeders, it is essen- work, its exhaust temperature will be
considerably higher than the other
tial to pressurize the injection system
with fuel gas pressure. This is accorp- cylinders.
The balance between cylinders is
lished by opening the angle valve near accomplished by adjusting the collar on
the top of the fluid supply tank to the injection valve. Turning the collar
clockwise will increase the valve lift
49
and more fuel will be admitted to that period, the timer automatically recon-
particular cylinder and, as it does nects the remaining shutdown function
more work, the exhaust temperature will switches into the instrument panel sys-
increase. By turning the collar coun- tem. The stop button is used to stop
terclockwise, less fuel will be injec- the engine-compressor during the 15-
ted to that particular cylinder and, as minute interval that the automatic
less work is done, the exhaust shutdown switches are not Operating.
temperature will decrease. This adjust- SAFETY DEVICES
ment is made using the spanner wrench
included in the box of parts. The in- Ajax engine-compressor instrument
jection valves should be adjusted until panels have a set of safety devices to
the exhaust temperatures of the cylin- shut down the unit in the event of mal-
ders are within 40° F. of each other function. The unit shutdown is accom-
when the unit is loaded. When the cyl- plished by closing the fuel shut-off
inders are in balance, the adjusting valve.
collars should be locked in place by Each safety switch is connected to
tightening the 1/4" set screw in the its individual indicating relay known
collar. as a "tattle tale". This relay is iden-
When installing new injection tified by a nameplate and if a specific
valves, the collars should be turned malfunction occurs, the relay that is
clockwise all the way in and then connected to the specific switch closes
turned counter-clockwise three complete the grounding circuit connected to the
revolutions. This position will give fuel valve thus stopping the unit. A
ample adjustment to balance the red button pops out on the front of the
cylinders. panel to identify which malfunction
shut the unit down. This red button
INSTRUMENT PANEL must be pushed in by hand to reset the
Ajax engine-compressors are normally relay before the unit can be started.
equipped with a custom enclosed weath- This annunciator relay requires only a
erproof instrument panel that provides momentary closing of the safety device,
all necessary information for daily op- thus the unit will shut down even in
eration. Usually included in the panel the event of a malfunction which then
are the following gauges and corrects itself.
annunciators: (1) Engine jacket water The safety switches furnished on the
temperature, (2) Compressor jacket unit should never be disconnected. The
water temperature, (3) Discharge gas cause of a recurring malfunction should
temperature, (4) Suction pressure, (5) be determined and corrected before re-
Discharge pressure, (6) Interstage starting the unit. Any other action
pressure (when required for multi-stage could cause serious damage to the unit.
operation.) The jacket water Safety devices normally included on
temperature gauges are equipped with the Ajax engine-compressor include the
adjustable high temperature shut-down following:
contacts, while the pressure and OVERSPEED SEUTDOWN DEVICE - The
discharge gas temperature gauges are unit overspeed shutdown device uses
fitted with adjustable high and low a spring loaded weight, located in
shutdown contacts. the rím of the flywheel, installed
Additional items included on the in such a manner that the
instrument panel are a 15-minute spring centrifugal force of the weight is
wound start-run timer switch and an opposed by the action of the
emergency stop button. The 15-minute spring. As the speed of the
start-run timer is used at starting to engine in-creases, the weight
deactivate all of the safety shutdown compresses the spring and the
switch functions, except engine over- plunger extends outward from the rim
speed. At the end of the start-run of the flywheel until it strikes and
trips a lever on the overspeed
50
switch assembly. The lever being pressure indicating gauges are
tripped releases a spring loaded equipped with separately adjustable
plunger which then closes the contacts to shut down the unit on
overspeed switch, thus grounding the excessively high or low gas pressure
ignition system through its related and final discharge temperatures.
panel mounted tattle tale relay. The Each panel is normally supplied with
over-speed switch bolt spring is suction and discharge pressure
factory adjusted to trip the switch gauges (and interstage pressure
at 25-50 RPM over maximum. The gauges when required), as well as a
overspeed trip lever must be temperature gauge to indicate the
manually reset before the unit can gas temperature at the outlet of the
be restarted after a shutdown. final stage of compression on the
LOW OIL LEVEL - Float operated unit. (Interstage discharge
safety switches are provided on the temperature gauges and shutdowns can
crankcase and the force-feed lubri- be supplied where required.)
cator. These float operated switches RIGE LIQUID LEVEL IN SEPARATORS -
serve a dual purpose; first, these It is common practice on gas
switches act as a float operated compressor packaging to install
valve to permit automatic refilling separators in the lines before the
of the unit crankcase and force-feed intake of each stage of compression.
lubricator reservoir, and second, The separator removes liquids from
they act as a shutdown switch the gas passing through and prevents
through the tattle tale relay system possible damage to the compressor
in the event that the refill cylinders.
operation is not completed. All separators are fitted with
RIGE ENGINE JACKET WATER AND COM- automatic dump traps to remove the
PRESSOR JACKET WATER TEMPERATURES - collected liquid. In the event of a
These combined indicating malfunction, the float operated high
thermometers and high temperature liquid level shutdown switch will
shutdown switches protect the power ground its respective tattle tale relay
and compressor cylinders from damage before the liquid in the separator
due to possible loss of coolant and rises to a dangerous level.
consequent overheating. These Other shutdown devices are available
switches are electronic and and may be installed in the field. The
thermocouple actuated devices instrument panels are usually equipped
The thermocouple should be inserted with spare openings to install addi-
in the top (outlet or hot) side of tional tattle tales and shutdown
the engine or compressor jacket gauges.
water system at the point where the COMPRESSOR CYLINDER ASSEMBLY
jacket water leaves the cylinder.
The compressor cylinder jacket water PERFORMANCE
shutdown switch should be adjusted By using a few simple checks, the
to shut the unit down if water operator can quickly determine if the
temperature exceeds 160° F. The compressor cylinder is operating pro-
engine jacket water shutdown switch perly. The most obvious indication of
should be adjusted to shut the unit trouble is reduced capacity.
down if the water temperature When a capacity reduction is
exceeds 206° F. noticed, feel the suction valve covers.
ABNORMAL GAS TEMPERATURES AND A warm or hot suction cover indicates a
PRESSURES - The gas temperature and leaking valve. The discharge valve
51
covers will naturally run hot. However, the unit over various ranges of suction
if one cover is hotter than others, or discharge pressures. Sometimes
valve leakage is indicted. unpredictable situations occur which
For a unit having two or more are not covered by the performance
stages, it is a good idea to record the curve and adjustments are made by
normal interstage pressures and "feel". The problem with operating out
temperatures. Many times a change of of the scope of an appropriate
interstage conditions is merely performance curve is that the operator
normal reaction to a change in the can easily exceed the allowable rod
unit's overall compression ratio. load or encounter a very low or
However, if the first stage suction negative volumetric efficiency without
conditions and the final stage dis- having knowledge of doing so. A typical
charge pressure have not changed, then problem encountered is the result of
any change in interstage conditions adding too much clearance volume to the
should be investigated. head end of a cylinder. A point is
An abnormal increase in interstage reached (usually about 30% volumetric
pressure indicates problems in the efficiency) where the head end is
higher stages; whereas, an abnormal incapable of producing a specific
decrease in interstage pressure indi- capacity. The crank end of the cylinder
cates problems in the lower stages. will still be producing, but the head
Temperature gauges may be installed end will be erratic or non-producing.
to show the operating gas temperature In this situation, the head end works
out of each stage. Any significant rise continuously on the same volume of gas
in temperature from a cylinder indi- and generates undesirable heat. A
cates an abnormal condition, such as a better arrangement, producing the same
leaking valve or a broken ring. capacity, would be to operate single
acting.
CLEARANCE ADJUSTMENT - COMPRESSOR
SINGLE ACTING OPERATION
One of the methods used to alter the
horsepower and capacity of a compressor When the required capacity drops
cylinder is to change its head end the volumetric efficiency of the cyl-
clearance percent. "Normal" clearance inder below 50% it may be desirable to
percent is by definition the minimum operate single acting with one end of
possible and will result in maximum the cylinder unloaded. This can be ac-
horsepower requirement and capacity. complished by removing the suction val-
Reduction of horsepower and capacity is ves from the end to be unloaded. The
accomplished by the addition of clear- cylinder will then compress gas only on
ance volume, usually to the head end of the loaded end.
the compressor cylinder. Various de- HYDROGEN SULFIDE GAS
vices, such as bottles, plugs and pock-
ets, are available to add clearance Compressor cylinders are specially
volume. built whenever the gas contains more
than 32 grains of hydrogen sulfide
PERFORMANCE CURVES - COMPRESSOR (.05% by volume). Higher percentages of
Performance curves are normally hydrogen sulfide increase the precau-
furnished which illustrate the proper tions taken.
clearancing required to fully load
52
COMPRESSOR CYLINDER MAINTENANCE
COMPRESSOR CYLINDER BODIES SHRINK LINERS
Cylinder bodies are provided with Shrink liners are held in place by
water jackets which are accessible by an interference fit Between the O.D. of
removing the cover plates. Cover plates the liner and the I.D. of the cylinder
should be removed periodically for in- body. Shrink liners do not have flanges
spection and cleaning of the cooling or "O" ring grooves.
surfaces. To remove a shrink liner from the
Some cylinder groups are solid bore compressor body, it is necessary to
types and the pisten runs directly on place the body off center on a boring
the cylinder body bore. If the gas is mili and cut out part of the liner.
clean and proper lubrication is main- Usually the liner will collapse due to
tained, solid bore cylinders will the interference fit stresses when the
rarely need reconditioning or replace- liner wall becomes thin.
ment. CAUTION:
The walls of solid bore cylinder Do not apply haat to the compressor
bodies are thick enough to allow re- body in an attempt to remove the
boring to a maximum of 1/8" larger dia- liner. Distortion and warpage of the
meter as a preparation for building the compres-sor body can result.
cylinder bore back to original size. Prepare the cylinder body for a new
Oversize pistons and rings are not liner by heating the body in a 350° F.
normally recommended. oven for three hours. The cylinder body
must be stood on end and a provision
SLIP LINERS made to locate the liner in the body in
Slip liners are held in place by the same position as the original
the cylinder head pressing against the liner. The liner must be dropped into
flange portion of the liner. Slip lin- the heated body immediately (in a mat-
ers do not have interference with the ter of seconds) before the liner can
cylinder bore and can be removed easily start heating due to contact and radia-
atter the cylinder head has been remov- tion of the hot cylinder body. Cooling
ed. In order to get the liner started of the liner with dry ice can be em-
out of the body, the unit should be ployed to gain additional assembly
barred over with the end of the pisten time. If cooling is used to shrink the
rod pushing against a wooden block in liner, beware of frost action which may
the valve ports of the liner. Once the cause the liner to stick while being
liner is out far enough to get hold of installed.
the liner flange, remove the pisten and Once the new liner has been
rod assembly. The liner can new be reinstalled and the cylinder body has
moved by hand. cooled off, drill lubricator holes in
Use new "O" rings, new back-up the liner by using the holes in the
rings, and new liner flange gaskets body as a pilot.
when installing a slip liner. Be sure In cases where heating the cylinder
factory flange gaskets are used, since body is impractical, a hydraulic press
improper materials and sizes contribute can be employed to install the liner if
to flange failures. adequate precautions are taken to pre-
Slide the inner flange gasket over vent damage to the mating surfaces.
the liner O.D. before installing back- COMPRESSOR PISTONS
up rings and "O" rings on the liner.
Slide the liner into the cylinder body The design and material of the
making sure the oil hole in the liner pisten will vary considerably with the
is aligned with the oil hole in the class of compressor. Generally, cast
cylinder body. Repiace the cylinder iron pistons are used in the smaller
head and torque the cylinder head nuts diameter and slower speed units while
53
aluminum pistons may be used in the cylinder wall.
larger diameter and higher speed units. The side clearance between the ring
End clearance between piston and and the groove in the piston should
cylinder heads should be adjusted as also be checked. Make sure the ring is
outlined in start-up procedure. free in the groove in all positions and
that the side clearance is not excess-
COMPRESSOR PISTON RINGS ive. Rings and grooves should be clean-
The piston rings should be fitted ed to remove all dirt or carbon that
to the cylinder separately to check for may have accumulated during previous
proper end gap. Too small a gap will operation. A ring having too much side
allow the ends of the ring to butt clearance tends to tip in the groove
together when the ring is heated to causing wear, while a tight ring can
operating temperature and cause excess- stick and fail to seal.
ive wear of both the ring and the cyl- End gap and side clearance of new
inder. A gap too large will allow blow- pistons and new rings vary according to
by to wipe the lubricant from the ring material and diameter:
PISTON RING CLEARANCE
MATERIAL CARBON FILLED TEFLON PEEK FILLED MATERIALS
Side Clearance .988 x Nominal Width .994 x Nominal Width

Tolerance + .000 + .000
- .004 - .004
End Gap (90 cut) .022 x Nominal Dia. .011 x Nominal Dia.
(45 cut) .016 x Nominal Dia. .008 x Nominal Dia.
Tolerance + .001/in. Dia, -.000 + .001/in. Dia, -.00
Minimum .010 .010
Rings should be checked for lock nuts. Be sure to loosen set screws
roundness to insure a minimum wear in sufficiently to prevent damage to
time. Also check that the ring can be threads when removing piston rod.
depressed below the diameter of the Note:
piston at all points. Some crossheads use two locking
Coat the rings and ring grooves screws. When installing the piston rod,
liberally with clean oil before insert- use a thimble which slips over the
ing the piston into the cylinder. crank end of the piston rod and pre-
Stagger the end gaps of the piston vents the threads on the rod from dam-
rings with respect to one another. aging the wiper packing or pressure
packing. Thimbles are listed under
COMPRESSOR PISTON RODS "Special Tools" in Section 3. Check
Piston rods are generally chrome torque table for proper lock not
plated high strength alloy steel. torque.
Special materials or coatings are used COMPRESSOR PRESSURE PACKING
when the gas is corrosive. It is
essential that the rod be free from Particular care should be taken
scratches or nicks to prevent damage to during the initial break-in period of a
the oil scraper or packing rings. compressor piston rod pressure packing.
The piston rod is screwed into the It is recommended that the lubricator
crosshead and locked by set screws and feed rate for the packing be set at
54
twice the normal rate and the compress- assembled, a screw driver should be
or run unloaded for 15 minutes. used to lift each plate off the seat at
Periodic inspections should be various points around the plate to
established to detect packing malfunc- insure each plate is free at all
tions before they cause major damage. points. Assemble the valve into the
It is good practice not to disturb the compressor cylinder with extreme cau-
packing as long as it does not leak. tion making sure suction valves are not
However, continued use of a leaking installed in discharge ports or vice
packing can result in damage to the versa. Trace the flow of the gas and
piston rod. Inspect the piston rod for remember a valve opens in the same di-
surface defects such as scores or rection as the flow of the gas. Use a
shoulders. If the rod is not in good screw driver to verify the flow of gas
condition, it should be refinished or through each valve before it is in-
replaced. stalled in the cylinder.
The teflon packing rings use a To get the maximum efficiency from a
teflon/metal combination. The teflon compressor cylinder, the inlet and dis-
ring faces the pressure; whereas, the charge valves must be clean and tight.
metal ring backs up the teflon ring to Valves should be inspected periodic-
prevent the pressure from extruding the ally. Experience will tell how often
teflon between the rod and the packing they must be cleaned under the particu-
case. lar operating conditions.
If valves require frequent cleaning,
COMPRESSOR VALVES the cause may be one of the following:
Ajax compressor valves are the A) Excess oil, or an improper grade
plate or poppet type. Some valves have of oil. This will cause carbon to
a separate plate covering each port in deposit on the valves, and also
the seat and are called "individual throughout the compressor cylin-
ring" plate valves. Other valves have der. Use only enough oil to prop-
the individual plates webbed together erly lubricate the cylinders and
to form a single plate and are called be sure to use the best grade
"portad" plato valves. The plate or oils.
rings seal on the smoothly ground B) High gas temperature, which is
surface of the seat. The valve guard usually the result of leaking
houses the springs which hold the plate valves as explained in previous
or rings against the seat. discussion under Compressor
Valves should be removed periodic- Cylinders.
ally for inspection and cleaning. Check C) Dirty intake gas. This situation
the valve plates for cracks, indenta- can usually be remedied by in-
tions, wear and distortions. If any of stalling a filter in the intake
these conditions exist, replace the line.
valve plate as well as the springs. New The underside of cylinders have
valve plates are finished on both valve cages with set screws to keep the
sides, so either side can be used ini- valve seat gasket, valve assembly and
tially. If plates are reused, they valve cage from falling out of the
should be assembled in the valve the cylinder while the valve cap gaskets
same way they carne out. Plates should and valve caps are being removed or
not be "turned over" since the guard installed.
and springs remove the smooth surface Tighten all valve cap nuts finger
from the guard side of the valve plate. tight before applying a wrench to them.
Examine the gasket seating surfaces Using a torque wrench, tighten the nuts
on the valve, as well as in the cylin- opposite each other a little at a time
der body. These surfaces should be free so the valve cap will brought down
from nicks, scratches, and dirt. evenly on the valve cap gasket.
When compressor valves are Torque values for tightening nuts
are listed in Section 3.
55
COMPRESSOR CYLINDER AND PRESSURE PM:RING LUBRICATION
CAUTION: READ TBESE INSTRUCTIONS TBOROUGHLT BEPORE SELECTING A LUBRICANT.
COMPRESSOR LUBRICATION For lubricators having the glycer-
ine filled sight feed, about 3 to 4
For type of lubricating oil see "drops", or expulsions per minute
Engine/Compressor Oil Specification on up the wire is equivalent to 1
page 30.2.
Pt./Day.
(c)On the initial start-up of new
CTLINDER LUBRICATION QUANTITIES compressors, and especially if high
Wide variations in actual field humidity and/or "wet" gas condi-
operating conditions, such as the tions are encountered, the aboye
cleanliness of the gas, the "wetness" rates should be nearly doubled for
of the gas and even the type of gas, the first few hours of operation,
make it almost impossible to specify and then cut back, generally to
the exact quantities of lubricants the point of sufficient
required for compressor cylinders. lubrication.
However, for dry, clean gases, such as (d)Since it is always less expensive
those mentioned under "Oil Specifica- to start out over-lubricated than
tions," the following rules will it is to replace or repair scored
generally suffice to provide ample cylinders, rings, rod packing and
lubrication after initial run-in: rods, it is never-the-less undesir-
(a)The actual volume of lubrication able and uneconomical to continue
used is generally expressed in at such a rate. Over-lubrication
pints-per-day. Since the rubbing can cause excessive oil carry-over
surface of a reciprocating motion into air lines, instrumenta, and
is involved, an amount of oil even to the end products, plus re-
equivalent to 1/2 pints per day sulting in over-carboning and gum-
per one million square feet of ming of valves and rod packing.
swept area plus a "pressure Therefore, after the first few
factor" amount should give satis- hours of lubrication, and it is
factory results. From this rule observed that more than sufficient
the following formula can be used: lubrication has been achieved, the
(31.4 x Bore Dia. x Stroke x RPM) rate can be cut back by steps of 2
+ (333 x Disch. Press.) to 3 drops per minute, until the
The answer to this formula gives a desirable oil film, as noted in the
factor which represents the rela- next paragraph, is attained.
tive amount of lubricant required (e)By shutting the compressor down,
per cylinder. To convert this and removing one or two of the
lubrication factor to valves, inspection of the cylinder
pints/day/cylinder, move the deci- interior can be made for sufficient
mal point six (6) places to the lubrication. Over-lubrication is
left. Another conversion that will the result of excessive oil, and
express the quantity in approxi- small puddles of oil will collect
mate drops/minute is to move the in the cylinder low spots. This in-
decimal point only five (5) places dicates a cut-back in lube rate is
to the left. required. On the other hand, if
(b)Since cylinder lubrication is near- surfaces are dry and no oil film
ly always supplied by a sight feed appears present, the rate should be
lubricator, which permits visual increased. A generally accepted
observance of pump strokes and "so test for sufficient lubrication is
many drops per minute" of lubricant to blot the rubbing surfaces with 3
being supplied to each cylinder or 4 layers of tissue or cigarette
point or points, it is convenient paper, immediately after removing a
to be able to express "Pts./Day" valve, and following a shutdown. A
in "Drops/Min." A rough rule of yellow stain or clear oily dis-
thumb for making this conversion coloration through the first layer
is to consider approximately 10 and into the second layer of tissue
Drops/Min. equal to 1 Pt./Day. is indication of proper lubrica-
This is equivalent to about 14,400 tion. Lube rates should be adjusted
drops per pint, considering the up or down according to the indica-
drops to be approximately 5/32" in tion of this test. Any evidence of
diameter, which is the average gray, black, or bronze discolora-
size put out by most gravity and tion in the oil may indicate abra-
vacuum sight feed lubricators. sion, scuffing, or some other mal-
56
function which should be investi- six (6) places to the lett. Another
gated prior to start-up. conversion that will express the quan-
(f) Certain air compressors having rod tity in approximate drops/minute is te
packing lubricated by carry-over move the decimal point only five (5)
from the compressor cylinders can places to the left.
be checked for sufficient lubrica- Drops/minute, start-up rates and
tion by applying tissue test to final lube rates are determined in the
the rod surface through the dis- same manner as that outlined under
tance piece opening. The lube "Cylinder Lubrication Quantities".
rates, as calculated by the formula See Table 5B Chart for estimating
in paragraph "a", should be suffi- rod lube rates in accordance with the
cient for such cylinders and aboye formula can be used for
packing arrangements, but the final convenience.
lube rate will generally be depen- 4. PIRE-RESISTANT LUBRICANTS
dent upon maintaining a proper oil
film on the rod surface, rather Quite often, in air compressors and
than on the cylinder surface. certain process applications, synthetic
However, since applications and or fire resistant lubricants, such as
cylinder sizes can vary, both Pydraul AC, Fyrquel (formerly Cellu-
surfaces should be periodically lube) and Houghto-Safe, are used for
checked for determination of which cylinder and rod lubrication. General
surface takes precedence in experience, to date, indicates that
deciding the final lube rate. these lubricants will do a fair job
(g) To summarize the aboye: providing the compressor is properly
prepared, the lubricant is carefully
1. Careful selection of the lubri-
cant for the specific application selected and is supplied in sufficient
is most important. quantity.
Initial preparation of the machine
2. Periodic examination of the cyl-
inder and rod is required to as- is very important since gaskets, seals,
certain that the proper lube rate o-rings and paints must be compatible
is being applied. with the particular lubricant being
used. A check with the particular lu-
3. Extended over-lubrication is as
detrimental as under-lubrication. bricant manufacturer will reveal the
The former will result in excess necessary compatible materials.
oil and heavy carbon deposits, When synthetic lubricants are to be
while the latter may result in used, it is recommended that the cylin-
scoring and scuffing. ders be broken-in using a heavy mineral
(h) TD-1165, Table 5A Chart, for oil (SAE-60 or greater), and running
estimating lube oil rates in for at least 150 hours or until the
accordance with the formula given cylinders have taken on a glazed
in Paragraph (a) can be used for appearance. After break-in, the proper
convenience. grade of synthetic lubricant can then
be used. Since the synthetic lubricants
3. PACKING LUBRICATION QUANTITIES may vary in density from those of
Since many lubricated applications hydrocarbon lubricants, the required
require rod pressure packings having lube rate at initial use should be
one or more points of lubrication sup- increased by 1-1/2 to 2 times those
plied by individual pumps on the same rates established in Articles 2 and 3
lubricator supplying the cylinders, the for cylinder and rod pressure packings.
same notes applying to "Cylinder Lubri- However, the same general tissue test
cation Quantities" generally hold true. for sufficient surface film is usually
However, a safe quantity of "rod oil" satisfactory. Also, a possible cut back
for the same dry, clean gases listed in lubrication rate may be realized
after just a few hours of operation.
previously is 3/4 pint per day per
million square feet of swept area plus In cases where it is absolutely
a "pressure factor" amount. This is impossible to break-in the compressor
cylinders on a mineral oil and the syn-
expressed by the formula:
thetic lubricants must be used, it
(47 x Rod Dia. x Stroke x RPM) + (75 x should be noted that the danger of cyl-
Disch. Press.) inder scoring does exist. Extreme
The answer to this formula gives a cleanliness of suction piping is an
factor which represents the relative absolute must if scuffing is to be
amount of lubricant required per rod. avoided, since the film thickness of
To convert this lubricant factor to synthetic lubricant is generally less
pints/day/rod, move the decimal point than with the mineral oils. It is fur-
57
ther recommended that the particular der and rod pressure packing. Construc-
grade of synthetic lubricant be on the tion may even be such that it is im-
higher side of the available viscosity possible for any accidental lubrication
range, and that the highest lube rate to reach the rod pressure packing and
possible be used for the first 100-150 cylinder. The sealing and rubbing ma-
hours. This initial lube rate must be terials for piston rings and packing
at least 1-1/2 to 2 times the rates rings are of a suitable filled Teflon
established in Articles 2 and 3. material that has self-lubricating
Occasionally, units must be started- characteristics, and is specially se-
up and broken-in during low ambient lected to meet all the operating con-
temperature conditions. When this is ditions of each specific Job. The pis-
the case, lubricator heaters are usu- ton is supplied with rider rings or
ally necessary to insure that the lub- bands of the same material so that
ricant is warm enough to flow properly. there will be no metal-to-metal rubbing
This requirement is due to the gener- parts in the cylinder.
ally higher viscosity index of most "Normal-lukm" applications
synthetic lubricants as compared to generally have suitable metallic piston
that of hydrocarbon lubricants. rings and packing rings that depend on
If it is decided to change from a an oil film to prevent metal-to-metal
hydrocarbon lubricant to a synthetic contact in the sealing and rubbing
lubricant on a machine that has oper- area. The
ated for a period of time with the normal lube rate is that amount sup-
former lubricant, it is best to select plied to the cylinders and rods in ac-
a Fire resistant fluid that is compat- cordance with the rules of Articles 2,
ible with most standard materials of 3 and 4. Remember though, what may be
construction. Ore-lube is one such normal for one application may be too
lubricant. If such a fully compatible much or too little for the next. It is
fluid is not going to be used, then also possible to have non-lube con-
gaskets, seals, o-rings and paints may struction, as outlined aboye, and sup-
have to be changed out since the lubri- ply normal lube to the cylinders and
cant may have a deteriorating effect on packing even though the sealing and
these items. When making such a change, rubbing trim is Teflon. However, normal
it is advisable to check cylinder lube in this case would be less than
internals and to remove all carbon normal lube for the same application
deposits on valves, etc., to prevent with metallic rings.
their being loosened by the new "Semi-1u~ is generally considered
lubricant. as one-half the "normal-lube" rate.
Since there are a number of differ- Sometimes this can be accomplished by
ent synthetic lubricants on the market special lubricants. It can also be
today, it is best to get all the accomplished by the use of suitable
available information about the speci- Teflon piston rings and packing rings,
fic lubricant to be used prior to es- with no rider rings on the pistons.
tablishing materials of construction, "Mln-lube" is defined as a con-
start-up and normal operation rates. trolled amount of oil at about one-
For example, Flurosilicone lubricants quarter the normal rate of lubricant,
are coming into use in compressor as spelled out aboye. For special ap-
applications and the lube rates for plications, this can sometimes be
this particular synthetic material may accomplished by use of the exotic
be as low as one (1) pint per month; Fluoro-silicone lubricants, where the
therefore, it must be stressed that the lube rate may even be as low as one
lubricant manufacturer be consulted pint per month with metallic sealing
prior to the use of any new and unfa- and rubbing materials. However, the
miliar synthetic lubricant. standard cylinder construction for min-
lube consists of suitable Teflon rider
5. ADDITIONAL COMMENTS AND GENERAL and seal rings on the piston and Teflon
INFORMATION rod pressure packing. In other words,
The terms "non-lube", "normal-lube", construction is identical te that de-
"semi-lube" and "min-lube" are fined for non-lube, the exception being
often applied to compressor that the cylinders and packing are
applications. A brief description of supplied with lubrication points. When
each of these terms is as follows: this is done and lubrication is applied
"Non-lube" is described as those properly, long ring and packing lite
applications where the compressor cyl- results with little or no rod or cylin-
inders are constructed so that no lub- der wear. (This, of course, results
rication need be supplied to the cylin- only if the gas is free of dirt or fine
58
abrasives which is always detrimental
regardless of the type of construction
and lubrication used.)
For min-lube, viscosities of the
lubricant should be lower than for nor-
mal lubricated services. The following
is recommended:
Viscosity 0100° F Viscosity 0210° F
130 to 160 SSU 40 to 45 SSU
(These viscosities are equivalent to
SAE 5 to 10 weight oil.)
A straight napthenic oil will
generally be a better choice than a
paraffinic oil; however, here again the
lubricant must meet the specifics of
the application.
It may be detrimental to the Teflon
trim to use lubricants with higher
viscosities than those listed. Also,
proper min-lube construction can some-
times be operated non-lube if all
parameters are receptive to such
operation with Teflon trim.
One important word of caution with
regards to min-lube applications: too
little lube may cause a gumming and
high wear condition that is worse than
no lube at all. Some min-lube appli-
cations will require as much as what is
normal lube for others, while other
min-lube applications may work satis-
factory at low lube rates.
"Accidental-lube" is some oil that
gets to the packing and/or cylinders in
an unknown and uncontrolled amount.
"Minimum-lube" is the quantity of
oil which reaches the packing and cyl-
inders in a controlled amount tht has
been determined to be the least amount
necessary for satisfactory life of the
rubbing parts.
59
TABLE SA
LUBRICAT1ON RATES FOR COMPRESSOR CYUNDERS
1:1-11455
i 5 s Rr
COMPRI!~ CYll NUR LUIR RATIS II
11111:2111 IiIIIIII
gag■guimagairmoseemom ■
7
maipA
proppam
.do .
To determine annount of lubricant rectuired, foltow
venial
"Mil" and the,' vertically to "discharge prez- me
•4
, 1,,frencr.,,ifiil..„',i,i,,",-.
Ji.n..,u. or.,.-,,,- :
from vrai ! III
.117'
r i:Itril I Vd y *Zti leo sukil:
5;i 1 eiyl;d. r Id: 'd,i27$1,:r'
ElAIII j 4 apero • ■
lene in "droga pa minvte ".
441r7411
at 11" cundir with en 11" stroke ■
Examplet An
enpafating 327 RPM e, 200 PSIG discherg• z
~sur* recluirse •bout 2.1 Ota./dax or ebout ■
21 droga/mire.
110111111
AddkAill 11:1
NOTE—Read inoructions in 5ection 5 l'aforo
E
ii
thie cher?, L4iirg
N/IBLIIIIIIIIIMU
~MB ME■O E■MIIMM
11~~11 ME E MI■EMMEMMEMMOMMEMIMPTII
MIZWERTMWMMUIrn■ME■U■ MIRMEM E■ME ■OWOMM
N*■LIWWWWWWWWIEM E E■II■ MEZO
MME~AMM■MOIRIUMME■II ME■E■111■MOMM■OCWOM■
IIIM III
MINIONMEMOMMEMEWA 11 U■III
■ME■MOMMUOMEMEW=3 IIIMMEMMOMM2OME2
MIMMOCUMESIOM ■MiUMME
MOMEMZEMSESSIM, ■E■MRSORSOMM EOW=UO■O
UMMICOMEMOSOMZEZE
=mnemeaggammumaerammammem
Mil urnsmmumrowns
■m weamayermsweamma
mmosliesomaemam ma■m
m mumumstassoIll ■ ■ MEZIEblii E
ammummusis mseaezelzammemmom momum m■m
mmumummummu memwoaaameramomm m .
■UMWMUM■M ■
wp-al malwrwdmadgm. m
mPirg .....
.. 1 .........
2 41 - •S •
. I•
TABLE 5B
LUBRICATION RATES FOR COMPRESSOR PISTON ROD PRESSURE PACKING
i vsz-ho, 11(11_111_1111_11 To-l166
a
1 as
RA ROO PRISSUR1 PACRING LUIR RAID
"` To determine amount of lubricant recluirse!, follow

vertical line up from sPecific "rod clierneter" to 111
prora« "ermita", Memo horizontaily to operering 1.
"RPAA" and 1+1111 V erticaily to "discharge oree- ■
m
00° Mis
sore" iine. Folla« horixontally to l ett from hori•
Odie* and raed "pinte par day". Follow mi
eontelly to right and read •pproxirna te 4/quiva•
a lent in "drope per minuta". III

■
i2. A40A111111
ex Example: A 21/2" diameter rod with are 11"
Ip stroke odemting et 140 RPM at 1500 P510
V di:chupe prisma recluirse &Paul .7 pint par
clay or *bao 7 drops Par minuta. .1
NOTE: Reid inettoctione in Sowtion 5 befo'', II
*sirva t+lia cher,.
-! -1 111111 ■
III
1.
■mul samánbasamw
PPM LIT
• is sii mis
' Ild
1111111,11Erall
IJIT IIIII
001% '
01 1 II
mim III III
ii11111111111
p%
1.....
g 15001 -50110@al
10111111 I Il
d
,,, . . . . „-02 11111/1 "
1111:0:1
I
1 .-ígil
.... I 1 III
NEME Malla ill lig nal El II
I
60
SECTION 7
PREVENTIVE 1104211TENANCE
A good preventive maintenance operation. If too much is added, drain
program can add years of trouble-free back to the running mark. Too high a
performance at minimum operating cost. level will not only waste oil, but will
The first requirement for this kind of also cause ring sticking, excessive
maintenance is consistent observance of port carboning, rapid ring and cylinder
good operating practices. In the opera- wear, loss of power and oil leakage
tion of Ajax engine-compressors, the around shafts and gaskets.
following points will contribute to
maximum performance and economy. WEEKLY:
Check fuel gas pressure and adjust,
Cleanliness is most essential in the
if necessary. Once fuel pressure has
operation and maintenance of the unit.
been adjusted for smooth operation,
Clean air, clean water, free from
further adjustment should be required
scale-forming minerals, and clean
only when appreciable load changes are
lubricants should be the rule - always. made or fuel gas composition changes.
When starting a cold engine, allow
Check spark plug and maintain proper
to idle until warm before applying
load. gap.
When operating on capacitor
Before starting, it is always good
discharge ignition system (Altronic),
practice to lubricate cylinder walls by
spark plug gap should be set at .030
pumping lubricator hand flushing units
inches.
with the piston at various posítions. Note:
Observe that the cooling water
Because of greatly increased spark
system is full and operating properly
plug life gained with the capacitor
before starting. Be sure that all water
discharge ignition system, the economic
connections are tight.
advantage of platinum point plugs with
Under no circumstances should a
this system is questionable.
large amount of cold water be allowed Drain any accumulation of fluid from
suddenly to enter a heated engine fuel gas volume tank.
cylinder. Check water level in radiator or
In freezing weather, all parts which
cooler.
contain water and which are subject to
freezing should be carefully drained MONTHLY:
and anti-freeze added. Always mix anti- Check air filter elements, clean or
freeze and water in clean container replace if necessary. Air filters
before adding to the cooling system. should be checked after heavy dust
Always be certain that there is storms. Check water level in cooling
sufficient oil in the crankcase and in system. Drain the scavenging chamber to
the force feed lubricator before remove accumulation of spent lubri-
starting. cating oil.
Every precaution should be taken to NOTE:
prevent the entry of water into the
DO NOT DRAIN WEILE ENGINE I$
lubricating system.
Do not exceed the rated speed for RUNNING.
normal operation. SEMI-ANNUALLY:
The cause of any unusual noise or Test all safety devices to make sure
knocks should be investigated immedi- they are properly set and operating.
ately. Locate the cause instead of Inspect and change spark plugs if
experimenting with adjustments. necessary.
Inspect and tighten all exposed nuts
SUGGESTIONS FOR PREVENTIVE MAINTENANCE
and fasteners.
PROGRAM Inspect and clean compressor valves;
DAILY: replace worn or broken parts.
Check the lubricator oil level to
ANNUALLY:
make sure that the oil from the reserve
Replace spark plugs and cables.
tank is maintaining proper level
Check alternator at reliable
through proper functioning of float
authorized service station.
valve in lubricator compartment.
Inspect governor and replace worn
Check sight feeds to make sure each
parts.
pump is functioning.
Clean and inspect lubricator and
Check crankcase oil level. When
adding oil, bring oil only up to the replace worn parts.
Clean breather caps on the
running level mark when unit is in
crankcase.
61
Thoroughly clean all dirt BI-ANNUALLY:
accumulation from the radiator and/or Inspect and, if necessary, replace
cooler and check for leaks. worn piston rings, thoroughly cleaning
Inspect and replace worn cooling piston and ring grooves.
system fan drive belts. Inspect and, if necessary, replace
Drain and flush crankcase. crosshead pin bearings.
Remove cylinder head. Inspect intake Check cooler tubes and remove any
and exhaust ports and remove all carbon accumulated deposits.
in ports.
Check compressor piston rod pressure
packing.
SECTION
SERVICTNG FOR EXTENDED FERIODS OF STORAGE
PREPARING FOR EXTENDED STORAGE system.
(9) Remove mixer manifolds and apply a
(1)Drain cooling system by removing light rust inhibiting oil to the
pipe plug at bottom of cylinders. seating surfaces of valve strips.
Make sure complete cooling system (10)Remove spool from throttle valve
is drained at all low points. and thoroughly oil spool and bore
(2)Drain oil from crankcase, and ahead in body before re-assembling.
of crosshead guides. Remove side (11) DO NOT drain fluid from gas
cover and wipe crankcase clean with injection system. Do not
rags. DO NOT USE WASTE OIL. Using drain oil from control box and
an oil can with a good grade lubri- lubricator.
cating oil, squirt oil on piston (12) If unit is moved from foundation
rods and around stuffing box and and flywheel is removed from
connecting rod bearings. Wipe oil crankshaft, coat the crankshaft,
on both upper and lower guides and and flywheel bore with grease.
replace cover. Also, plug all openings; such as
(3)Remove crankcase top covers and air starting and rotary throttle
wipe remainder of crankcase clean. valve inlets.
Squirt oil in and around main bear- (13) Remove overspeed switch bolt from
ings and crank pin bearings. Remove flywheel, clean and apply oil to
breather caps and wash in solvent plunger and bore before re-
and blow dry with air. Then reoil assembling. Oil overspeed shutdown
filter element and install on unit. mechanism.
(4)Drain scavenging chamber to'remove (14) Remove distance piece covers and
sludge and replace plug. wipe chamber clean. Thoroughly
(5)Swab engine piston rods with oil wipe compressor piston rod with a
while pistons are at back dead rust inhibiting oil. Rotate crank
center. to cover maximum length of rod.
(6)Remove engine cylinder heads and Pump lubricator feeds by hand to
swab cylinder bores with oil while flood stuffing boxes and
piston is at back dead center. In- cylinders.
stall cylinder head and rotate (15) Remove compressor valves and coat
crank so that piston is about mid- all components with oil. Before
stroke. Pump each cylinder lubrica- replacing valves, squirt oil on
tor pump ten or twelve times by cylinder wall and on piston rod.
hand, thus flushing oil around (16) Pump each lubricator pump ten or
piston and rings. twelve times by hand to lubricate
(7)Using 3/8" plywood, cut a disc that compressor piston and pressure
will fit inside tapped holes for packing. Rotate crankshaft to
the exhaust flange. Insert disc distribute oil.
over exhaust opening. Draw flange (17) on cylinders equipped with vari-
capscrews up tight, thus sealing able volume clearance pockets, oil
cylinder from dust and other piston and threaded rod. Cover
foreign matter. exposed rod with grease.
(S) Apply liberal amount of grease to (18) All exposed valve stems should be
all ball and socket joints used in protected with grease.
linkage arrangement for fuel
62
(19)Cover all flange openings with sure that all working parts are
plywood covers cut to suit. operating freely.
(20)Plug all threaded openings. (7)Clean air filter.
(21)Disassemble trap, clean and oil (8)Remove all plywood storage covers
orifice and seat before and plugs from flange openings and
reassembling. threaded connections.
(22)Grease fan shaft and bearings. (9)Tighten fan adjusting screw or
(23)Loosen idler pulley to remove load idler to apply proper tension to
from V-belts. V-belts.
(24)Protect instrument panel and any (10)Be sure to check adjustment of
other exposed area which might be overspeed shutdown switch and
damaged during storage. adjust if necessary.
(11)Refer to Section 4 for start-up
instructions.
SERVICING APTER EXTENDED PERIODS IN

STORAGE
Ajax has taken every practical
precaution to prevent corrosion or rust
in bearings, piston rods, crossheads,
metallic packing, cooling system, etc.,
by treating all of these parts with
approved rust inhibitors. However, the
following additional precautions should
be taken when placing engine-
compressors in service after long
periods in storage after shipment from
the factory, or other extended storage
periods.
(1)Remove side and top covers and see
that the crankcase is clean. Fill
crankcase with oil. See lubrication
recommendations in Section 5.
(2)Remove cylinder head and clean cyl-
inder bore. Swab the cylinder with
clean lubricating oil to provide
initial lubrication for piston and
rings.
(3)Inject a light oil in the various
bearings, as well as around cross-
head and on piston rod. For.a com-
pletely thorough job of recondi-
tioning, the metallic packing
should be cleaned and oiled. Pack-
ing on lubricator shaft should be
loosened and oiled, and the gover-
nor lever shaft euter bearings
should be oiled.
(4)All screws and nuts which hold gas-
kets should be tightened, as with
lapse of time the various gaskets
may have shrunk. This applies par-
ticularly to cylinder heads.
(5)Carefully drain the lubricator be-
fore filling. After filling the
lubricator, disconnect each of the
oil feed lines, operate the lubri-
cator flushing units by hand and
see that oil flows freely through
each oil line, and through the
check valve.
(6)Remove governor cap and inspect
governor weight pins and remove any
corrosion which has accumulated
during storage period. Oil and make
63
SECTION 9
TROUBLE-SEOOTING GUIDE
MANUAL
DIFFICULTY POSSIBLE CAUSE OF DIFFICULTY REFERENCE
Page
(1) Engine will * Ignition.

not fire. a. Check spark plug gap. 36
b. Check altronic ignition. 38 (600), 40 (800)
c. Check timing. 38 (600), 40 (800)
d. Check for incorrect
ignition coil. 38 (600), 40 (800)
* Shutdown switch grounding out ignition. 50
* Lack of compression. 11, 12, 33
* Faulty gas regulator. 8
* Linkage to throttle valve improper length
thus not opening throttle valve when
governor calls for more gas. 37
* Fuel pressure too high or too low. 8, 25, 49
* Fuel pressure line to tank shut off. 8, 25
* Volume tank filled with fluid. 8, 25
* Air in hydraulic system. 49
* Regulator flow off or too small orifice. 8
* Needle bypass valve(s) open. 49
* Injection valve(s) not adjusted. 49
* Air cleaner plugged. 9, 36, 63
* Air flow restricted. 9, 36, 63
* Improper hydraulic fluid in injection
system. 44
* Reed valve broken in air check valve. 34
* Blind gasket between exhaust flange and
cylinder was not removed at installation 63
(2) Lubricator * Air lock in lubricator pump. 28

fails to pump. * Check valves to the cylinder plugged. 28, 29
* Faulty check valves in lubricator. 28
* No oil in the lubricator. 28, 29, 56
* Lubricator drive failure. 29
* Suction strainers in the lubricator
plugged off. 28
64
MANUAL
Page
(3) Excessive * Oil level too high. 8, 28, 61

crankcase oil
consumption. * Worn stuffing box packing. 13, 35, 36
* Scored piston rod. 35, 36
* Air filter plugged. 9, 36, 63
When both the lubricator and crankcase are

connected up to a single ,,uxilary oil
supply, check to make su: that high oil
consumption is not a res ... of excess oil
through the lubricator.
(4) Racing or * Improper spark plug gap. 36

irregular
operation. * Gas volume tank too small. 8, 25
* Faulty gas regulator. 8, 25
* Governor binding. 37, 49, 63
* Throttle valve sticking or binding. 49, 63
* Worn connection in governor linkage.
(5) Detonation or * Overload. 6

pinging.
* Oil used for cylinder is too ligh-_ and
is burning. 29
* Fuel gas pressure too high. 8, 25, 49
* Wet fuel. 25
* Timing too early. 38
* Air filter plugged. 9, 36
(6) Knock in * Restriction of air through air cleaner. 9, 36

engine.
* Fuel gas pressure too high. 8, 25, 49
* Wet fuel. 25
65
MANUAL
Page
(6) Knock in * Air-fuel mixture too rich. 8, 25

engine.
(cont.) * Injection valve(s) adjusted too far
closed. 49
* Improper timing. 38
* Loose crank pin bearings or crosshead

pin bearings. 10, 12, 13, 14
(7) Engine slows Excess load. 6

down. (While
firing * Piston or rings sticking because of
regularly.) improper lubrication. 28, 29, 30
* Hot bearings. 10, 12, 13, 27, 32
* Ports plugged with carbon. 30
* Insufficient fuel system. 8, 25, 49
* Faulty ignition coil. 40
(8) Engine will not * Overload. 6

pulí load.
* Fuel pressure too low. 8, 25, 49
* Improper air-fuel mixture. 9, 25
* Throttle valve linkage incorrectly

adjusted. 35, 49
* Volume bottle and/or fuel line

regulator and orifice in regulator
inadequately sized. 8, 25
* Loss of compression due to worn or

stuck rings. 12, 30, 34
* Improper timing. 38, 44
* Ports plugged with carbon. 30
* Exhaust pipe improper size or length. 9, 25
66
MANUAL
Page
(8) Engine will * Air cleaner plugged. 9, 36

not pulí load.
(cont.) * Muffler too small or carboned up. 9, 25
(9) Overheating. * Overload. 6
* Improper exhaust pipe length. 9, 25
* Air filter plugged. 9, 36
* Muffler or exhaust ports plugged. 9, 25
* Air passage through the cooler restricted 32,62
* Recirculation of hot air through the

cooler. 32
* Improper running timing. 38, 44
* Cooler plugged. 32, 62
* Excessive carbon build up in port and

rings. 12, 30, 34
* Entrained liquids in fuel gas. 25
(10) Excessive * Entrained liquids in fuel gas. 25

carbon
deposit in * Oil feed rates from lubricator too high. 29
ports and
rings. Leakage of oil from crankcase past
piston rod stuffing box. 14, 35, 36
(11) Hot main or * Oil too heavy or used too long. 28, 29, 61
crank pin
bearing. * Water in oil. 28, 29
* Crankcase oil low. 8, 26, 27,
* Insufficient bearing clearance given

after an inspection or overhaul. 10, 12, 13, 14, 32
67
MANUAL
Page
(12) Burning of * Gas pressure too high. 8, 49

engine
piston. Too rich mixture. 8, 25
* Excessive carbon deposits. 29
* Oil in lubricator too light. 29
(13) Backfiring. * Improper timing, ignition or fuel 38
* Replacement alternator of wrong design. 38
* Excessive carbon deposits in ports. 29
* Fuel gas pressure too high. 8, 49
(14) Engine stops. * Spark plug gap excessive. 36, 61
* Air cleaner plugged. 9, 36
* Faulty ignition. 39
* Overload. 6
* Loss of fuel gas pressure. 8, 49
* Regulator frozen up. 8
* Safety switch grounding out ignition. 50
* Broken spark plug wire. 36, 61
(15) Out of * Reed valves broken in air check valve. 34

balance.
* Injection valves incorrectly adjusted. 49
* Spark plug fouling or ignition problems. 36
* Port carboning. 30
(16) Cylinders will * Improper hydraulic fluid. 44

not stay
balanced. * Injection valva stern not lubricated. 49
68
MANUAL
Page
(17)Injection Loose valve seat in injection valve. 49
valve stays
open. * Injection valve stern not lubricated. 49
* Fuel gas pressure too high. 8, 49
(18)Higher fuel * Insufficient fuel system. 8, 25

pressure
than Regulator too small or not equipped with
recommended proper orifice.
is necessary
in order to Regulator spring selection wrong.
pull rated
load. Volume tank too small or too great a
pressure drop between tank and engine
throttle valve.
(19)Muffler * Overfueling. 8, 49
glowing red.
* Using oil with too low flashpoint. 30
* Plugged muffler. 9, 25
* Overload. 6
* Defective fuel gas regulator

(Hole in diaphragm) 8
69
TD- 1 1 69
COMPRESSOR
TROUBLE SHOOTING CHART
POSITIVE DISPLACEMENT COMPRESSORS
Check List for Compresor impection and Obsarvetion
PROBLEMS
I
•
I á.
Ow over DUals
NUAIZERS 1P4 PROILIM COLWAN O
h
INDICA7I ORDER IN WHICH S u II
I
I. ci 1 Z 1 11 ', 1 .. -1 VII
Compressee
POSSILLE CAUSES SHOULD el I2* y L i ii 1.!
II TRACED / 1 T-. 7,
T; Ei 11 ii "I 1 . 'i 11 I= : Ili ii' l'i
12 vn
5:
22 id «: Lt 14 Ir11
70 ut» 1 a11 3*.r 34 I• 41 4i 31 -
u lot -1,11
Restricied Suction Line 4 4
Dirry or Defectiva Air Filtro 3 3 3 5 5
... ...
wfon tu &Token ~yes L. P. ' 1
2 1 2 2 1 3 4 1 3 á 6
Worn or Broken Valva% H. P. 1
Defectiva Unloadinq System L. P. 2
1 2 1 9 4 1 2 4 3 4 5 7
Defectiva Unloading System H. P. 2
Excesa,• System Leekage 5 3
Soesed ¡momees 6 6 3 3 7 8
- . - -
Worm Pistas Rings L P. 5 9 6
7 4
Worm P■ tton Rings H. P. 1
System Demend Estirada COMDI411401' Caloscity 5
Inadosuals Cooling Water Ouanvity á 4 1
■
Excessive Discharge Premura 4 1 12 9 2 3 5 2 1 6
Inadeouane Cylindef Lubncation 6 10 $ a 1 1
inadnuove Running Creer Lubrication 1 ' 1 5
Incorrect E'ectrical Characteristics 2
Motor Too Small 5 1
us ...
sla Escralisqr &Bit Tension 2 7 7
- . .
Vollag• Los.. 6 6
4II
V Loma FlywhInel or Pulley 7 2
Excets,..* Mar.rld Cle.f1D1C11
i
Ñ Leo.* PiltOrl Rod Nut
5
4
tob
o loes* Motor Rotor or Shift 9 6 ,.
ii• Escess.fa Crotsheag Clair ranfe 3 .
insuf-f ■ cient Hired Clearonca 2
Lisos* Piston 8
Running unloaded Too Long 2'
Imoroper Foundation or Orouting 8 5 . .
Wedges Left Under Foundation 10 .- •
Misal.gnment (Duplex Tybe) 3
Pishrsg irnofoperly Suoported 1 ,
Abnor".1 Inter :41er Pressure 7 •
7 .... 4
....
Dirty I ntercoolor 4 6 6 11
Dirty Cylinder Jacket* 3 5 2 10

Motor 0,srioad Ralas, Trioped 1
Excesiva Cylindef Lubncation
2 a
7 11 9 1 2 2
Incofrect Lubricating Oil
7
Discharge C.45 Temoereture Too High 4
3 3
liquid Carnpoyer
,
4 4
Din, Rvst Entering Cylindef
Resonant Pulsation (Inlet or DitchatO•)
• !Mor VAN**
Net*: Also refer ro Comoressor Cylinder Data in Section IV.
70
WARNING
• Proper length of studs and bolts is important for proper thread engage-
ment. Before removing any studs, measure stud height from machined
surface and position replacement stud to same height.
1
▪
-
•)
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CAPS, BARS BED TO BE MATCS-LIARKED
AS 5110." (1 2-3-4) TO Dasun RE-ASSEMBLY 114 CORRECT LOCATION
MAMI REARDI6 TEI CRANICSFIAET MAWETOLL

CLEALUICE IALL DEARDélS)
k .0046 -.0076"
RUN-IN VkLUE 5 5 1i.-LIS. MAQUE-

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52
Print by DONWHEELER on 01/13/00—Note:

ToROoE 50 -FT .18S.
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36
IMMALM 7aJ4 I YALUE 1S 5

41 11..115. TOROUE-
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15/ -USE LOCT1TE $TODLOcx No. vi NO1D1E-

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P POSPON Mi:CUNEAD P01 SCARN6 .009'...015*- 10 TE CIIECR£D TIMO fIJIL
14' OIL 014045-S0 NOT ORAN IMF 5 93 mAl INF RAI SPOTS ARE
DANT 15 RUNNING MOLE 8EF0RE AND %TER Asir« wo
u UNGES ne SET SCRE11? ICIES 15 INSTALLED AND IRIT 15 ICRODED
As- DDRiNG PERICOIC oft. cNANGE. FACA END
CAVrTY 10 ISE DRAINED 4 FLUSHED
SEPARATE OF CRANKASE.-REPLENISH ELYwEEL
END CMIPI FUTH SWE APPROKINATE
OF OIL REMOVED BEFORE START-UP.
(IF UN1T 15 EQUIPE» 141111 CRANKCASE TAIILE *A"
MAXE-UP DE SURF F1U.. LIME 15 5NOT OFF NET FIUIT
zunia biuumes ITEHS: 66, 67, 68. 69, NOT ILLUSTRATED
170111 19/8'
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Printby DON WHEELER on 01/13/00--Note:
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W 1-1-1 1-4J 1.1-3 U- 1-14 LLI W LU LU W LLI W
4 O r 4 O 4 O C., C., CO c.,
CC,
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4
.2 .4 tr e .r... • "--
• • CO c.C. c., co cc,
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• . . . . • • 0 •
. r-- CO CO 11, CO CO •—• O ••••,- O .....,

o o0 O o CO r— o o o LO o o
o .— kx, era 14", eta ..-- ..— «,--- «.— Cr, r ..--
N- CV ..-- ...— ,-- .— ,r•-• •■-- ,— N 1::, ■-•
cc. . • • • e • . ce. . •
• = =V = = •
b•C CM 0 Cra01,0c0000Y0:10,
CNJ Le, LID CO cr, O C,J CO ...s. cA

iJ
CM
S CC
CU LL
S
Z S _U
W 4
CL
1 .9 h-
4 4 4 4 4 4 4 4 4 4
UJ UJ W W W W UJ UU W W
cf? ••-• ••■■.
CO CO CO CO CO CO CO c9 CO CO
co 0,2
CO ,- CO
o, c., CO N- O r-
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• • • • c• • • • Lo
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ENGINEERING - SALES - SERVICE DATA
Engines Pumps
COOPER ENERGY SERVICES
Compressors
ESS-G-75I
SOI.IR GAS
March 17, 1975

REPLACES BULLETIN ES3-C-56S DATED 8-25-75
WHAT IS IT?
Gas is classified as sour if it contains hydrogen sulphide; sweet if
it is free from sulphide odors.
THE EFFECT OF SOUR GAS ON GAS ENGINES AND COMPRESSORS.

Sulphides in fuel gas will combine withwater to formhydrosulphuric
acid. The amount of sulphides in fuel gas which will cause pitting of cyl-
inder walls, valves, or piston rods, and/or gumming and plugging of ports,•
is greatly affected by the annount of water present in the cylinder. This
water may be drawn in with fuel. gas or formed from condensate on cylinder
walls as a product of combustion. By employing an efficient separator,
and maintaining cylinder water jacket temperature at optimizm operating
temperature so that water resulting fromcombustion does not forra on cyl-
trider walls, a much higher concentration of sulphides can be tolerated than
would otherwise be possible.
Because hydrogen sulphide concentration is referred to variously

as grains per one hundred cubic feet, and in percentage by volume, we are
showing below how to convert from one to the other.
CONVERSION:
636 grains of hydrogen sulphide per 100 cu. ft. of gas = 1% of vol-
ume at 14.7 PSIA and 60°F.
1210 grains of sulphur dioxide per 100 cu. ft. of gas = 1% of volume
at 14.7 PSIA and 60•F.
7000 grains = 1 pound.
Natural. gas weighs approxirnately 4.8 pounds per 100 cu. ft.
TO CONVERT TO PERCENT BY VOLUME:

Example: 400 grains of hydrogen sulphide per 100 cu. ft.
400 grains /100 cu. ft. = .63% by volume

636 grains/100 cu. ft.
TO CONVERT TO PERCENT BY WEIGHT

400 grains /100 cu. ft. 400
= 1,19% by weight
7000 grains x 4.8 - 33,600
1.0 SYSTEM DESCRIPTION
The Altronic I 1-cylinder system is depicted below; the principie of operation

is the same for all Altronic I variations.
The alternator (A) provides the power for th electronic box (B) mounted to
it. The electronic box (8) rectifies the alternator's AC output to DC, stores
the energy in a storage capacitor and contains an SCR switching device. When
the external pick-up coil (C) is triggered by the rotating magnet (D) (either
disc or flywheei mounted), the SCR in the electronic box is activated thus
releasing the energy in the storage capacitor to the ignition coil (E) which
steps-up the voltage to fire the spark plug.
SPARIC
PLUG
A. Alternator D. Magnets triggering

B. Electronic Box E. Ignition Coil
C. Pick-up Coil
-3-
2.0 PAtTS IDENTIFICATION AND SPECIFICATION
2.1 PARIS LIST - ALTRONIC I

REP. NO. PART NO. DESCRIPTION *
1 510 454-U Coupling
la 902 478 Spring pin
2 See pg. 6 Bearing-shaft
3 See pg. 6 Housing
3a 510 541 Ventilator
4 102 103 Nameplate
5 102 106 Part no. decaí
6 160 001 Magnet-rotor assembly
7 171 001 Stator - red leads
171 003 Stator - blue leads
7a 110 447 Grommet
8 110 453 Spacer
9 510 462 0-ring
10 110 452 Cover
11 110 469 Gasket kit
lía 901 317 Washer
12 902 480 Screw
13 See pg. 6 Electronic box
13a 503 105 Tubing
14 410 045 Sleeve
15 902 503. Washer
16 902 487 Snap ring
NOTE: Reference nuabers with a letter suffix are part of the assembly
of the same number without the suffix. Example: (la) is part
of (1).
2.2 BEARING-SHAFT IDENTIFICATION - Refer to exploded view on pg. 4.

BEARING-SHAFT PART NO. (2) BEARING EXTENSION LENGTH
110 459 0.55"
110 465 1.03"
110 466 0.85"
110 467 1.46"
110 471 1.33"
-5-
3.0 TROINILESHOOTING
3.1 SENO« TEST - ALTRONIC I

A. Connect complete system as shown below. Virn alternator shaft one or
more revolutions by hand; then push the pick-up coil down squarely against
the flush magnet of the magnet bar. A spark should jump a 7mm gap as
shown. If performance test is failed, proceed to step 3.1D. below.
1. SPIN ALTERNATOR SHAFT

2. PUSH PICK-UP DOOM SQUARELY AGAINST ~LIT
ILLIZ
+-
CAD INF PICK -UF COIL
HAQIET MR
nUSH MAQ4ET
B. Connect voltmeter to electronic box as follows; tura alternator shaft

one or more revolutions by hand:
POSITIVE NEGATIVE METER

METER LEAD METER LEAD SCALE READING
Center terminal Ground 250VDC 101 074 Box - 105-126 VDC
of Elec. Box 101 077 Box - 105-126 VDC
181 004 Box - 130-157 VDC
C. If tests 3.1A. and 3.1B. are passed, the Altronic I unit is OK.
D. If either 3.IA. or 3.1B. is failed, the problea may be in the:
1. Connection between stator (7) and electronic box (13)
2. Alternator stator winding
3. Electronic box
E. Remove two screws (12) holding box (13) to alternator. Check connections
between box and alternator. If OK, unplug stator leads from box.
3.2 STATOR (7)

A. Check stator winding (7) with ohmmeter as follows:

METER LEAD _
- LEAD SCALE READING
Stator lead Stator lead RX10,000 171 001 - 4,800 + 10% ohms
171 003 - 1,100 + 10% ohms
Stator lead Alt. Case RX10,000 Either Stator - Infinite
NOTE: The 171 001 stator has red leads; 171 003 has blue leads. Replace
stator if defective.
-7-
3.5 BENCH TEST - ALTRONIC 1-6
A. Connect complete System as shown below. Turn alternator shaft one or
more revolutions by hand; then push the magnet bar clown squarely against
the "A" pick-up of the pick-up module. A* spark should jump a 7mm gap
as shown. Repeat the sequence aboye using "B" and then "C" pick-up. If
performance test is failed, proceed to step 3.5D. below.
B. Connect voltmeter to electronic box as follows; turra alternator shaft


White lead of Ground 250VDC 181 003 Box - 105-126 VDC
5-pin plug 181 003-X Box - 130-157 VDC
C. If tests 3.5A. and 3.58. are passed, the Altronic 1-6 unit is OK.
D. If either 3.5A. or 3.58. is failed, the problem may be in the:
3. Electronic box
3.6 STATOR (7)


Stator lead Stator lead RX10,000 171 001 - 4,800 4. 10% ohms
171 003 - 1,100 .0 10% ohms
Stator lead _ Alt. Case RX10,000 Either Stator - Infinite
-9-
4.0 SERVICE - ALTRONIC I UNIT
A. The unit breaks clown into two mejor parts: the Alternator and the
Electronic Box. Remove the two screws (12) holding the electronic box
(13) to the alternator. Unplug the tw/ alternator leads from the
electronic box and separate the box from the alternator.
B. The procedures of this section require the use of an arbor press.
4.1 DISASSEMBLY - ALTERMATOR

A. Remove the remaining two screws (12) holding the cover plate (10) to the
alternator. Loosen the 0-ring (9) from housing (3).
B. Holding the assembly with the flange end up, remove the stator (7), spacer
(8), 0-ring (9) and cover (10) as a group; a vertical shaking motion will
. usually accomplish this.
C. Separate the stator leads and grommet (7a) from the cover (10).
4.2 DISASSEMBLY FRONT HOUSING ASSEMBLY

A. Drive spring pin (1a) out of coupling (1) and shaft (2) and remove
coupling.
B. If it is necessary to replace bearing-shaft (2), support housing on the
coupling end and press shaft out of the magnet-rotor assembly and housing.
C. Wrap magnet-rotor (6) in a cloth or paper to keep it clean.
4.3 REASSEMBLY - FRONT HOUSING ASSEMBLY

A. Press a new bearing-shaft (2) into housing (3) until it bottoms against•
the shoulder. Press on the outer race of the bearing. Housing (3) should
be supported behind the internal shoulder.
B. Clean all debris from magnet-rotor assembly (6).
C. Slide magnet-rotor assembly (6) over shaft with its plate facing inward
as shown below. Support the shaft on the coupling end and press
magnet-rotor assembly (6) on the shaft .650" from the housing surface
- see below.
NOTE: If the fit is loose, apply epoxy glue to the bore of the
magnet-rotor.
D. Slide coupling (1) on shaft and secure with spring pin (la) through the
coupling and shaft.
TD-1351
PAGE 1 OF 5
TROUBLESHOOTING ON ENGINE
1. IF IGNITION PROBLEMS ARE SU',1PECTED, FIRST CHECK THAT ALL IGNITION WIRING IS IN
GOOD CONDITION. MAKE SUBE GROUNO LEAD 15 RUN FROM THE NEGATIVE TERMINAL OF
THE IGNITION COIL (S) BACK TO THE ALTERNATOR HOUSING. CHECK THAT GAP BETWEEN
PICK-UP COIL ANO FLYWHEEL MAGNETS DOES NOT EXCEED 1/4" .
2. IF SYSTEM APPEARS TO BE INSTALLED CORRECTLY WITH ALL WIRING IN GOOD CONOITION,

FIRST REMOVE ALL SHUTDOWN WIRES FROM CENTER TERMINAL OF THE ELECTRONIC BOX ON
THE ALTERNATOR. THIS WILL ISOLATE THE SHUTDOWN SWITCHES ANO WIRING WHICH MAY
BE CAUSING THE PROBLEM BY PARTIALLY OR COMPLETELY SHORTING OUT THE IGNITION.
(NOTE: ELECTRONIC IGNITION IS MORE SUSCEPTIBLE TO SHORTING OUT FROM THIS SOURCE
DUE TO ITS LOW PRIMARY CURRENT OUTPUT.) ALSO REMOVE CAPACITOR LEAD IF ONE IS
PRESENT.
3. REMOVE WIRE FROM SPARK PLUG ANO HOLO APPROXIMATELY 1/4" AWAY FROM THE SPARK
PLUG TERMINAL TO CHECK FOR SPARK WITH THE ENGINE CRANKING OVER. IF THE IGNITION
SYSTEM IS FUNCTIONING PROPERLY, THE SPARK SHOULD JUMP AT LEAST 1/4" TO THE
SPARK PLUG TERMINAL.
4. IF THERE IS NO SPARK OR A WEAK SPARK IN TEST 3, CHECK FOR OUTPUT AT THE ELECTRONIC
BOX CENTER TERMINAL USING A SCREWDRIVER TO SHORT TO THE ALTERNATOR HOUSING.
a) A STRONG FLASH INDICATES THAT THE ALTERNATOR CONTROL BOX UNIT IS OK.
THIS CASE, FIRST REPLACE THE IGNITION COIL; IF THIS DOES NOT SOLVE THE
PROBLEM, REPLACE THE PICK UP COIL ASSEMBLY. IN GENERAL, A BAO IGNTIION
COIL WILL PRODUCE A WEAK SPARK IN TEST 3. A BAO PICK-UP COIL ASSEMBLY WILL
USUALLY RESULT IN NO SPARK. REPLACE ANY PICK-UP COIL WHERE THE GRAY CABLE
INSULATION HAS BEEN CUT OR DAMAGED.
b) A WEAK FLASH OR NO FLASH INDICATES A PROBLEM IN EITHER THE ALTERNATOR OR

ELECTRONIC BOX. ANY TYPE OF ERRATIC FIRING OR CONTINUOUS FIRING 15 USUALLY
THE RESULT OF A FAULTY ELECTRONIC BOX. REMOVE THE ALTRONIC UNIT FROM THE
ENGINE; THEN REMOVE THE ELECTRONIC BOX FROM THE ALTERNATOR AND DISCONNECT
THE TWO LEADS. THE ALTERNATOR'S STATOR WINDING MAY BE EASILY CHECKED IN THE
FOLLOWING WAY: TURN THE ALTERNATOR SHAFT WITH THE TWO LEADS SHORTED TOGETHER.
A LOADING EFFECT WILL BE NOTICED AS COMPARED WITH TURNING THE SHAFT WITH THE
TWO LEADS SEPARATED IF THE ALTERNATOR STATOR IS OK. REPLACE STATOR WINDING IF
THIS IS NOT THE CASE. THE WINOING CAN ALSO BE CRECKED WITH AN OHMMETER FOR
CONTINUITY. NO READING (1NFINITE) INDICATES AN OPEN CIRCUIT ANO A DEFECTIVE
WINDING. REPLACE THE ELECTRONIC BOX IF THE STATOR WINDING CHECKS OK.
DO NOT DISCONNECT THE BLUE WIRE FROM THE IGNITION COIL ANO SHORT TO GROUND TO CHECK FOR
SPARK. THIS CAN DAMAGE THE ELECTRONIC BOX.
SPARE PARTS
PART NUMBER DESCRIPTION

101 074 1 cylinder electronic control box
101 077 2 cylinder electronic control box
110 016 stator winding (unserialized & S/N 1,000-4,500)
171 001 stator winding (S/N 5,000 & up)
501 061 ignition coil
101 065 pick up coil assembly - 33" gray, 60" blue
101 181 pick up coil assembly -180" gray,200" blue
101 062 magnet bar - 5-1/4" long
101 076 magnet bar - 8-1/4" long
ALTRON1C 1 REMOVE P1CK-UP COIL
To further test the alternator or electronic box, it is necessary to

remove them from the engine. First remove the pick-up coil connector
from the electronic box, being sure to unscrew the plug where the arrows
indicate. This Will avoid damage to the internal connections of the plug.
eitronie ECONOMY ENGINE COMPANY

•• GIRARD, OHM 44420
dIvision 712 TRUMBUU. AVENUE
PtioNe (216) 545-9766
TD-1351
PAGE 5 OF 5
•••
ALTRONIC 1 CHECK STATOR WINDING

In arder to check the alternator stator winding, the electronic box must
first be removed. An ohmmeter check for proper resistance is made across
the two red stator leads. Correct resistance readings are given in the
Service Instructions. It is important to reinstall the two nacer washers
Between the electronic box and alternator. If the gasket on the unit does
not have these, it must be replaced with a new gasket and washers. Part
number for the kit of these parts is 110 469.
altronic" ECONOMY ENGINE COMPANY

si
dwion 712 TRUMBUU. AVENUE • GIRARD. OHIO 44420
PHONE (216) 5454768
ALTRONIC., INC.
712 TRUMBULL AVENUE
GIRARD, OHIO 44420
%
SERVICE MANUAL
ALTRONIC I IGNITION SYSTEM

5000 SERIES S/N 5000 4 UP
IMPORTANT SAFETt NOTICE
The procedures called for herein require the use of special

tools and heavy duty :achine equipment. Personnel performing
such repairs should be trained in the use of such equipment
and be knowledgeable of their potential safety hazards so
as to be able to safely perfora the recommended procedures.
Proper repair and maintenance is essential to the safe and

reliable operation of this equipment and the engine to which
it is applied. Failure to follow the recommended practices
could load to potentially hazardous conditions. An iaproperly
installed or operating ignition system aay leed to improper
engine operation which consequently could pose the threat
of personal injury to operators or other nearby personnel.
FOR)! Al SM 5000 1-86

(Supercedes Fora AI SM 5000 2-85)
ALTRONIC., INC.
712 TRUMBULL AVENUE
GIRARD, OHIO 44420
SERVICE MANUAL
ALTRONIC I IGNITION SYSTEM

5000 SERIES S/N 5000 i UP
IMPORTANT SAFETY MUTICE
The procedures called for herein require the use of special

tools and heavy duty sachine equipment. Personnel performing
such repairs should be trained in the use of such equipment
and be knowledgeable of their potential safety hazards so
as to be able to safely perfora the recommended procedures.
Proper repair and maintenance is essential to the safe and

reliable operation of this equipment and the engine to which
it is applied. Failure to follow the recommended practicas
could leed to potentially hazardous conditions. An improperly
installed or operating ignition system may leed to iaproper
engine operation which consequently could pose the threat
of personal injury to operators or other nearby personnel.
FORM AI SM 5000 1-86

(Supercedes Form AI SM 5000 2-85)
1.0 SYSTEM DESCRIPTION
The Altronic I 1-cylinder system is depicted below; the principie of operation

is the same for all Altronic I variations.
The alternator (A) provides the power for tle electronic box (B) mounted to
it. The electronic box (B) rectifies the alternator's AC output to DC, stores
the energy in a storage capacitar and contains an SCR switching device. When
the external pick-up coil (C) is triggered by the rotating magnet (D) (either
disc or flywheel mounted), the SCR in the electronic box is activated thus
releasing the energy in the storage capacitor to the ignition coil (E) which
steps-up the voitage to fire the spark plug.
A. Alternator D. Magnets - triggering

B. Electronic Box E. Ignition Coil
C. Pick-up Coil
2.0 PARTS IDENTIFICATION AND SPECIFICATION
2.1 PARTS LIST - ALTRONIC I

REF. NO. PART NO. DESCRIPTION *
1 510 454-U Coupling
la 902 478 Spring pin
2 See pg.. 6 Bearing-shaft
3 See pg. 6 Housing
3a 510 541 Ventilator
4 102 103 Nameplate
5 102 106 Part no. decal
6 160 001 Magnet-rotor assembly
7 171 001 Stator - red leads
171 003 Stator - blue leads
7a 110 447 Grommet
8 110 453 Space?
9 510 462 0-ring
10 110 452 Cover
11 110 469 Gasket kit
lla 901 317 Washer
12 902 480 Screw
13 See pg. 6 Electronic box
13a 503 1.05 Tubing
14 410 045 Sleeve
15 902 503. Washer
16 902 487 Snap ring
NOTE: Reference numbers with a letter suffix are part of the asseably
of the same number without the suffix. Example: (la) is part
of (1).
2.2 BEARING-SHAFT IDENTIFICATION - Refer to exploded view on pg. 4.

BEARING-SHAFT PART NO. (2) BEARING EXTENSION LENGTH
110 459 0.55"
110 465 1.03"
110 466 0.85"
110 467 1.46"
110 471 1.33"
-5-
3.0 TROUZLESNOCTING
3.1 MICH TEST - ALTRONIC I

A. Connect complete system as shown below. Twrn alternator shaft one or
i coil down squarely against
more revolutions by hand; then push the pickup
the flush magnet of the magnet bar. A spark should jump a 7mm gap as
shown. If performance test is failed, proceed to step 3.1D. below.
1. SFIN ALTEKKATOR SHAFT

2. PUSE PICK-UF DONK SQUARELY AGAIRST »GUT
11.111111111.
+—
C AE
..1p21111 ALTERNATOR
PICK-u! COIL
COIL 11ffil Mil
u
NAGNET BAR
•
7 DM GAP FUER N4GNET
CARLO
B. Connect voltaeter to electronic box as follows; tern alternator shaft


Center terminal Ground 250VDC 101 074 Box - 105-126 VDC
of Elec. Box 101 077 Box - 105-126 VDC
181 004 Box - 130-157 VDC
C. If tests 3.IA. and 3.18. are passed, the Altronic I unit is OK.
D. If either 3.IA. or 3.1B. is failed, the problea may be in the:
3. Electronic box
3.2 STATOR (7)


Stator load Stator lead RX10,000 171 001 - 4,800 + 10% ohms
171 003 - 1,100 + 10% ohms
Stator lead Alt. Case RX10,000 Either Stator - Infinite
-7-
3.5 BERCI TEST - ALTRONIC 1-6
A. Connect complete system as sown below. Turn alternator shaft one or
more revolutions by hand; then push the magnet bar down squarely against
the "A" pick-up of the pick-up module. A' spark should juap a 7mm gap
as shown. Repeat the sequence aboye using "B" and then "C" pick-up. If
performance test is failed, proceed to step 3.50. below.
B. Connect voltmeter to electronic box as follows; turn alternator shaft


White lead of Ground 250VDC 181 003 Box - 105-126 VDC
5-pin plug _ 181 003-X Box - 130-157 VDC
C. If tests 3.5A. and 3.58. are passed, the Altronic 1-6 unit is OK.
D. If either 3.5A. or 3.58. is failed, the problem may be in the:
3. Electronic box
3.6 STATOR (7)


Stator lead Stator lead RX10,000 171 001 - 4,800 + 10% ohms
171 003 - 1,100 + 10% ohms
Stator lead Alt. Case RXI0,000 Either Stator - Infinite
-9-
4.0 SERVICE - ALTROMIC I UMIT
A. The unit breaks down into two mejor parts: the Alternator and the
Electronic Box. Remove the two screws (12) holding the electronic box
(13) to the alternator. Unplug the twa alternator leads from the
electronic box and separate the box from the alternator.
B. The procedures of this section require the use of an arbor press.
4.1 DISASSEMBLY - ALTERMATOR

A. Remove the remaining two screws (12) holding the cover plate (10) to the
alternator. Loosen the 0-ring (9) from housing (3).
B. Holding the asseably with the flange end up, remove the stator (7), spacer
(8), 0-ring (9) and cover (10) as a group; a vertical shaking motion will
usually accomplish this.
C. Separate the stator leads and grommet (7a) from the cover (10).
4.2 DISASSEMBLY FROMT HOUSING ASSEMBLY

A. Drive spring pin (la) out of coupling (1) and shaft (2) and ~ve
coupling.
B. If it is necessary to replace bearing-shaft (2), support housing on the
coupling end and press shaft out of the magnet-rotor asseably and housing.
C. Vrap aagnet-rotor (6) in a cloth or paper to keep it clean.
4.3 REASSEMBLY - FROMT HOUSING ASSEMBLY

A. Press a new bearing-shaft (2) into housing (3) until it bottoms against
the shoulder. Press on the outer race of the bearing. Housing (3) should
be supported behind the internal shoulder.
8. Clean all debris from magnet-rotor asseably (6).
C. Slide magnet-rotor asseably (6) over shaft with its plate facing inward
as shown below. Support the shaft on the coupling end and press
magnet-rotor asseably (6) on the shaft .650" from the housing surface
- see below.
NOTE: If the fit is loose, apply epoxy glue to the boro of the
magnet-rotor.
D. Slide coupling (1) on shaft and secure with spring pin (la) through the
coupling and shaft.
PREMIER
PREMIER P-55 PUMP
OPERATING INSTRUCTIONS
1. Fill reservoir with oil.

2. Loosen union nut on pump outlet.
3. Remove nozzle plug and fill sight
glass with oil. Prime by manually
pumping flushing unit until air free
oil is observed in drip tube and oil
level drops in glass.
4. Replace nozzle plug and tighten
union nut.
5. Maintain oil level in glass below drip
tube so drops can be observed.
FLOW RATE
1. Loosen lock nut on flushing unit.
2. 'Turn flushing unit ccunter-
clockwise to increase
3. Turn flushing unit clockwise to
decrease flow.
4. Tighten lock nut when desired flow
rate if achieved.
NOTE: PREMIER MODEL P-55 PUMP (#90100)

IS INTERCHANGEABLE WITH LINCOLN
#880187 AND MEGA #39315
PREMIER LUBRICATION SYSTEMS

14105 Packard Street • Houston, Texas 77040
Telephone 713 462-5255 • Fax 713 462-4027
630 Series
Fisher Controls Instruction Manual

630 Series Regulators
and Relief Valves
FISHERI August 1979 Form 1243
WARNING
Fisher regulators and relief valvas must be

installed, operated, and maintained in accord-
anca with federal, state, and local codas, roles
and regulations, and Fisher instructions.
immediately call a qualified technician in case
of trouble. Feilure to correct the situation
immediately may create e hazardous condition.
INTRODUCTION
Scope of Manual
This instruction manual providee operating, installation, ■•1111.5
maintenance, and parta information for the 630 Series

regulators and relief valvas. Figure 1. Spring-Loaded Type 630 Regulara,.
Description
The Fisher 630 Series consiste of self-operated. Type 830
Big Joe• pressure regulators and Type 630R relief valvas,
available in either spring-loaded or preesure-loaded
constructions. Pressure-loaded reguiators use a Fichar
Type 67, 67H, 1301F, or 1301G loading regulator.
Pressure-ioaded Type 630R relief valvas use a Fisher Type
67 or 1301 F loading regulator.
SpecificatIons
Tabla 1 lista the specifications for the 630 Series
Figure 2. Pressurs-Loeded Typo 630R Ralief Valva
constructions.
• F,ther Controls Cpmperly 1971

630 Series
Tabla 1. Specificattons
AVAILABLE See table 2 MATERIAL Standard: —20 to 150°F (-29 to

CONFIGURATION: TEMPERATURE 66°C)
CAPASILITIES Optional: —20 to 300°F (-29 to
ENO CONNECTION ■ 1 -inch or II 2-inch, screwed 149°C)
SIZES ANO STYLE
PONT DIAMETERS II 1 /8-inch (3.2 mm), II 3/16-inch
MAXIMUM Type 830 Regulators: See tabie 3 (4.8 mm), ■ 1/4-inch (6.4 mm). ■
NIMBARE INLET Type 830R Rilke/ Valvas: See 3/8-inch (9.5 mm), or ■ 1/2-inch
PRESSURES tablas 6 and 7 (12.7 mm)
OUTLET PRESSURE 3 to 500 psig (0.2 to 34.5 bar) with COEFFICIENTS FON Wide Open Ce -
RANIES intermediate values shown in RELIEF VALLE SIZINI 1/8-inch (3.2 mm) port: 13.5
tablea 4 and 5 3/16-inch (4.8 mm) port: 29.9
1/4-inch (6.4 mm) port: 53.5
MAXIMUM ALLOBI- See tablee 4, 5, and 7 3/13-inch (9.5 mm) port: 120
AILE OUTLET 1/2-inch (12.7 mm) port: 215
PRESSURES
APPROXIMATE 1-inch End Connection: 25 lb (11.3
MAXIMUM See tabla 3 WEIGHTS kg)
ALLOWAILE 2-inch End Connection: 301b(13.5
PRESSURE DROPS kg)
rabie 2. Avenible Configurations from extemai sources or from debris in the line.
The unit should be inspected for ~mg*
CONSTRUCTIOM
TYPE LOADING regularty and atter any overpressure condition.
Web Pressure Lew Pressure
PREMIO!!! REGULATORS %fore Installing, inspect the unit for any ~nye and any
830 Spring X X foreign material. The regulator or relief valve may be
830-101 Type 87 Regular« X X mounted in any position, however ensure that the flow
630-108 Typo 67I1 Regulater X X direction corresponda with the direction of the arrow on the
830.102 Type 1301F Regulates X X nameplate. Apply a good grade of pipe compound to the
830.107 Type 1301G Regulator X X mala threada of the pipeline.
RELIEF VALVES
X
530R-101 Typo, 67 Regulator
Vents
830R•102 Typ* 1301F Regula1ot X
830P.103 Spring X
WARNING
830R-104 Spnng X
When the un it is installed in an enclocad ares or

indoors, escaping gas may accumulate and be
1NSTALLATION an explosion hazard. Under these conditions
the vent should be piped away from the unit to •
freely ventilated outdoor location away from air
WARNING intakes, windows, etc. Protect all vent openings
against weather or the entrence of any foreign
Personal injury or system damage rney result if material that may plug the vent or effect
chis unit is installed where service conditions operation of the reguiator or relief valve.
could exceed the limita given in tabla 1. Inspect all vent openings periodically to be sun
Installations should be protected from physical they are not plugged. 1f the vent is in an
damage. Overpreasuring any portion of chis environment where freezing rain, ice, or snow
equipment may cause equipment damage, leak could clog the vent, it is recommended that a
in the unit, or personal injury due to bursting of weatherproof vent be usad.
pressure-conteining parte or explosion of
accumulated gas. Spring-loaded constructions have a screened vent
asaembly (key 27, figures 5 and 7) installed in the 1 /4-inch
System operstion within the limita of tabla 1 NPT spring case vent opening. 1f a remota vent is required.
does not eliminate the possibility of damage remove the vent assembly and install a remota vent line.
2
630 Series
April 1986
Errata Sheet
for
630 SERIES REGULATORS AND RELIEF VALVES INSTRUCTION MANUAL

Form 1243, August 1979
When replacing 630 Series regulator parts, the following Key Deecription Part /bombee
parts must be used to provide the corrosion resistance
capability detailed in National Association of Corrosion
Engineers (NACE) standard MR-01-75. Please add 23 Body. steel w/stainless steel pitot tubo'
1-inch 2N6990 X0092
these parts to the parts list on pagas 8 and 9 of your 630 2-inch 2N6991 X0032
Series regulator instruction manual: 52 Nace Teg (not shown), 18-8 !tenles* steel 1948034 X012
53 Teg Wire (not shown). 303 ataréate atad 1U7581 X0022
Kr/ Deecriptien Peat Nurnber
Please make the following additional changes and cor-

3 Spring Case. steei reCtiOnS to the manual:
For kr« pressure ~dor 3N6981 22012
For 11,0 presa re reguietor 3N6983 22012 1. On paga 5 in the Adjusting Spring-Loaded Regula-
6 Cap Screw (not usad w/km-pressure presura loaded
reguiatcr), pi sheet 1R8176 99012 tors and Relief Valves procedure, indicate that keys 1
12 Connecbx He•d Assembly (not usad w/low-presura and 2 are found in figure 6 as weli as in figures 5 and 7.
presa re looded requisa:Y)
For alirnvtxum blm, eluminum 16A9611 X032 2. On paga 6 in the third paragraph in the Maintenance
For surtiese ate. trim, Emitiese red 1P8465 X0012
procedure, chango the wording to read: "Except where
13 Oiaphregm Adapto'', steel
For Iow presura reguladse 2N6985 X0072 indicated, key numbers in the following procedures are
For tsigh presura regulettx 21.46987 X0042 shown in figures 5 and 6 for the spring-loaded Type 630
14 layer Assembly, stainiess Med regulator, in figure 7 for the spring-loaded Type 630R
For low pillastre regulator 182891 X0032 relief valva, and in figure 8 for the pressure-loaded Type
For NO presura regultor 182890 X0022
15 Pln, stainiess atecé OW0188 X0022 630R relief valva."
18 Inlet Adapter, sud
For use with 1-inch body 1F4798 X0022 3. On paga 7 in step la of the Replacing the Dia-
For use with 2-inch body 1F4799 X0022 phragm procedure, note that all key references refer to
19 Irle( Body (leaket, composlticn (2 req'd) OW0184 04022
figure 6 as well as figures 5 and 7.
20 S•et Ring. Veinte** sheet
1/8 inch (3.2 mm) port ~netos 1K4166 X0012
3/16 inch (4.8 mm) port die/rieles 1K4166 X0012 4. On paga 7 under step 9 of the Replacing the Dia-
1/4 inch (6.4 mm) port diameter 1K4164 X0012 phragm procedure, note the importance of centering the
3/8 inch (9.5 mm) port clemeter 1 K4163 X0012 diaphragm. Also note the importance of not twisting the
1/2 inch (12.7 mm) port ~meter 1K4162 X0012
diaphragm to levar attachment during assambly. Twist-
21 Valve Dák Assembly
Fa oreamos rangos to 200 oil (13.8 bar) ing of the diaphragm to levar attachment during assem-
Steiniesa steei holder, rubber disk 184500 X0072 bly Will cause sufficient friction to interfere with the
Stsrdess ate« holder, flucroelestomer disk 1E14500 X0082 proper operation of the regulator.
For vestirlo rengos Cove 200 psig (13.8 bar)
Stainiess ates' holder, nylon diek 1C1860 00082
Stainiess steel holder, TFE disk 1C1860 00002 5a. On pago 8, remove the figure and key number
22 Valls* Carrier, staaniees sten OW0186 X0022 references from step b as they are erroneous.
• Fletes Comas hssrsether e ene.. lee& M fiche Plesereed
~de Ihre Momeaban Pe presentad w, good tacs and belirred lo be acata* or en, «for ~Mor MIMItt ro the praetk,ctt nQr m a reCornrmoOMOn tO
Frenar Controle does not ouerantes satistactay resulta han ~os upan *Joh uM any producta aman n QailiCt wth any pastel Fon« Contrae reserves
~ton. Nothing menino/ ~MI I Po be coastnnid aa a werranty a the vit. stdxt t nace. lo Mar a momo, the deestn$ a specto*Scri a the
gusanos expresa a ?n'Oled, nigooring d'u porknnonock. mon2sitablity, fiMom prottote areatbed how.
Fa lunner inkamanon. ~pu:

Fishor Controls P O. Box 190, mraharown. 10~ 50158. U S.A.
Medwaf House, Knigrn Roed Stroxi. ROChESTER. Kern, Encuna 1.412 2E2
Prirm0 n USA
Description Pad Nurnbee
5b. On page 8, change the key 19 asbestos gasket Key
material so that it correctly reads "composition". 9 Cap Screw (for use wisteel diaphragm adapta.). pi
atoe(
For loes pressure regulatx 112 reozt) 1A35.26 24052
Sc. On page 9. change the key 23 part number for a 1- For high pressure regulator (6 req'd) T11206 28952
inch steel body with stainIess steel pitot tube so that it 10 Cap Screw (for use with cast iron diaphragm adapta).
correctty reads "2N6990 X0012". piated steel (10 req'd for iow pressure reguiator &
4 redel for high pressure reKjutator) 1A3525 24052
11 Diaphragm
5d. On page 9, note that the key 30 hex nut is for use Neopreno (1 req'd)
with only the key 19 cast iron diaphragm adapter. For low pressure regulator OW0200 02192
For tugh pressure regulator OW0199 02192
Fluoroeiastomily (2 req'd)
5e. On page 9, change the key 38 asbestos gasket For bow oreamos regulator OW0200 X0022
material so that it correctty reads "composition". For high pressure regulator OW0199 02402
12 Connecta Heed Assembly
5f. On page 9, changa the key 40 copper & asbestos For pressure-loaded loes-pressure regulator onty
1C3000 X0012
gasket material so that it correctly reads "copper & Aiuminum trim
Stainiess steel trim 103000 X0022
composition". For aii ochar regulatora
15A9811 X012
Aluminum trim
6. In table 8, page 11, change two occurrences of Stainiess steel inri 1P8465 00082
spring part number 0Y0664 000A2 to correctty read 21 vales Disk Assembly
For both spring-ioadied & pressure-loeded Tm, 530
"0Y0664 27022."
regulator
For pressure rings* to 200 psig (13.6 bar)
7. In table 9, page 12, change 4 occurrences of spring Brasa holder. rubber disk 1E14500 000A2
part number 0Y0664 000A2 to correctly read "0Y0664 SMriiess steel ~f. rubber disk 184600 00082
Brasa notó«. poryurethane disk 1P7351 X0012
27022."
Stainiesa steel hoider, poiyurethane disk 1P7351 000A2
Brasa Moder. fluom,kestorrier di« 184500 X0042
8. Update the parta list on pages 8 and 9 of the Stainiess steei noider. fluorolastcrner disk 184500 X0012
instruction manual to reflect the following changes and For presura ruges over 200 paila (13.8 bar)
Breas holder, nyicn disk 101850 000A2
additions: lotee° 00082
Stainkiss steel heder. nylon disk
Breas holder, TFE disk 1C1860 000C2
Stainiess ami holder. TFE disk 1C1850 00002
For Type 630R pressure-loaded reiiel Yalve
Brasa holder, rubber disk 103380 14012
Stainless steel holder, rubber dile 103360 35032
Pert *amber
Key Deecdpeee Brasa holder, TFE disk 103360 14012
Stainiess atiné holder. TFE disk 103360 35032
43 Diaphragm Protector (for usa ohlY when sPecified). TFE
Upo.< Spnng Sun. zinc For high pressure reguiator 1X8813 06242
4 18A9812 X012
For pressure ranges to 275 psig (19 bar) For low pressure regulator 1K8812 06242
For pressure ranges over 275 psig (19 bar) 18A95113 X012
630 Series
4
rabie 3. Maximum !Met Pressures and Pressure Drop: for ,Ltt 630 .guletors'
1/11-Inch (3.2 mm) Iff16
1/4-4ffeit (6.4 mm) 3/11-Inch (1.e- ,m) 1/2-roch (12,7 mm)
Deeoription 3/18-inch (4.8
men) Port Diemstor Port °lame*/ Port Dlemietsr
Port Dlemartbr
Maximum Alloweble
Iniet Preesure. 1500 (103.5)1 1500 1103.5)t 1000 (69)t 750 (51.8)t
Nig (fiar)
Maximum Alloweble
Pressure Drop t 1500 (103.5) 1000 (69) 500 (34.5) 250 (17.3)
Psi (Bar. Differential)
'Dots not armo ro teto/top rygulato• ot prIoleyfil4eadyd Typo IX nuoulator.
In Itt ge.M* TuN yot 5=05.4 sun, ot th• actual outtot prom." torno and cll• ~colon m'ovni" olmo" Ovo loe • aun pa• 5,1 oublt
CNISMOI aorIng ot 200 05.0 t1 4 Ion enO 3/1,449.11_1 oro") pon Plomoso ...P1 s moteo," eitor«.04to primo" breo ot 600 pa. (34 Ó.N.
ddibrerrfiel). tn. nom..noo. ano .4.014 ntet primo" .1 700 P.I.0 141.3 14.0.
t Nani• rale. 04C. N. normall y turnomod Po, prora" tO00.1 P120064. I t 4 14r. 6.14,..b41)- ro boleo 1.1.1". hluanta. I.rien re*" d.sat un
nonnOr tur.olnod fet nignN 01•11~re unas.
Tabla 4. Spring-Loaded Type 630 Regu/ator Outlet Pressure Limits

Deecription Low-Preseu e Regulartor Iligh-Preseure Regulen«
Outiat Pressure 3 to 10 8 to 20 17 to 30 27 to 40 ' 27 to 50 48 to 95 90 to 150 150 to 200 200 to 275 275 to 500
Renga, Paig (Bar) (0.2 to 0.7) (0.5 to 1.4) (1.2 to 2.0) (1.9 to 2.8) (1.9 to 3.5) (3.2 to 6.5) (8.2 to 10.3) (10.3 to 13.8) (13.8 to 18.9) (18.9 to 34.5).
and Spring OW0192 OW0191 OVV0190 0Y0864 OW0192 OW0190 0W01 9O 0Y0684 1.11489 11(3709
Peru Number 27022 27022 27022 0004.2 27022 27022 27022 000A2 27142 27082
Maximum
Allowable
Operating Outlet 10 (0.7) 20 (1.4) 30 (2.1) 40 {2.8) 50 (3.5) 95 (6.6) 150 110.3) 200 (13.8) 275 (18.9) 500 (34.5)
Pressure, Pitg
(Bar)
r
lifflit60 by
Maximum Oudot
Maximum
Pressure Over 2003 {13.8)
20 (1.41 203 {/.4) Emergeney 200 (13.8)
Presaure Settingl
Outlet
Nig {Bar)
Pressure
Maximum
Ernergenc-y Outlet
(Casing) 45 (3.1) 550 (38.0)
Preasure•
Puig (Bar)
1 040,114 to .ffillMél poro of thireguiblef oso *oro 4 podo propotto 11111~11 0111111CtléM Pr1~11111 3. Fa ~lo prersauftsertono lo 360 pare 124.1 bit en.r. Feor errturt tert.ps ara, 310 poi u24.1
n01ting by érnotioNt1 Villater linb, ~Me 111,0vol ,n 1/14 ,0*. tym, runas 0,~4yuy 4 latosa by maalfrn~ amlorganty .1144 0•14.■• 04 550 65.5 131.0 ball.
2. for e...fiel tomarme .Intris to 21 pa 40 (1.7 bol Only. FOr Inlistoo sanolps oro 213~11. 7 414 4. L141494 o 1.01..1 04 /neo" ua.o4n*.q Penli ney b<tw '1 Oolur M11/1" 15,11411"11•
cono primo," .5 limitad ly mon.," orwroanco oidor omito" or 45 mg 13.1 ball. vett".
Pressure-loaded constructions have a bleed orifice fitting Refer to the following tablea to determine pressure ratings:
(key 49, figure 9) insuflad in an extra outlet connaction of
the loading regulator. The function of this fitting la to bleed 1. Spring-loaded Type 830 regulators.
loading pressure during operation of the regulator or relief
valve. If remota venting is required, remove the screen from a. Inlet pressure and pressure drop-tabla 3.
the 1 /4-inch NPT opening and instan a remota vent line.
b. Outlet pressure-tabla 4.
2. Pressure-loaded Type 830 regulators.

Overpressure Protection
a. Main regulator inlet pressure and pressure drop -
As the case with most reguiators, the Type 830 spring- table 3.
loaded and presaure-loaded regulators have outlet pressure
ratings that are lower than the inlet pressure ratings. b. Loading pressure and outlet pressure-tabla 5.
Overpressure protection must be provided if the actual inlet
pressure can exceed the outlet pressure rating. Over- 3. Spring-loaded Type 830R relief valva pressure-table 8.
pressure protection is alio required for the loading
regulator and main regulator spring case of presaure- 4. Pressure-loaded Type 830R relief valva pressures-
Ioaded regulators and relief valves. tabla 7.
3
630 Series
1
Tabla 5. Pressure-Loaded Type 630 Regulator Loading Pressure and Out/et Pressure Lirnits
SIGN-PRES SUME REGULATOR
LOW-PRESSURE REGULATOR
Typ. 17H Typo, 1301F Type 13010
LOADING REGULATOR TYPE Typ. 67(4 Typo' 1301F Type 87
Typo 67
Maximum iniet Pressure 15001 1103.5) 1500' (103.5)

400 (27.6) 15001 (103.5) 250 (17.3) 400 (27.8)
to Loading Regulator, 250 (17.3)
Psig (Bar) 200 to 500
50 to 100 50 to 100 50 to 225
Outlat Prsssurs Rangul, 5 to 80 5 to 80 10 to 80
(3.5 to 6.9) 13.5 to 15.5) 13.8 to 34 5)
(0 .3 to 4.1) (0.3 to 4.1) (0.7 to 4.1) (3.5 to 8.91
Psig (Bar)
225 (15.5) 500 (34.5)
Maximum Operating Oudot 100 (6-9)
Presaurei, Psig (Bar)
Maximum Main Regulator
OutIet Pressure Ovar 200 (13.11) 200 (1 3.8 ) 2005 (13.8)
204 (1.4)
Pressure Setting 3,
Puig (Bar)
Maximum Emergency OutIst 250 (17.3) 550 (38.0)
110 (7.6)
(Casing) Presturs of Loading 887 (4.6)
Reguistor5. Puig (Bar)
Maximum Emergency Outlet 550 (38.0)
(Casing) Presura of 88 (4.8)
Main Regulator5 , Puig (Bar)
I trrn ed Dy membluall *imanten./ *uds.) ormaa))." ot 54 a4,g 14 5 berl. ~dm, is
t. urnrtea 10 :tu, Yillue by mteatelluen in I ir proe4140.• 10 Type 530 S. F. OUT14t brumo. ~LO 35012-mq 1241 bar). r.or hflhw 0n1oanw berlrgb..tiart
2. »Cok. te path )**4),)g rbluietstr sur TVOM 1130 rouo nrwmar. tonfteb 5 'bu..." eme.gobw! 0udes .11 otiaurN et 550 Oag 131.0 b«)-
3. Como?" to mar, el 0 betp ot tb. ~uy,' rnoy opyor rf potes grasos 4144441th•betual Onsgodne Lasáhoe r Owill1).1 et Ir101~4,•40,,W4 M mrkey Occur rl podes 0,1~1 U:44041M~
sollln, by 40nOurn0 Qr.ww triar 111001 IbOOrn 1110 1010 1.0110 of 104~1 OrsIMIIII 10 111441 va4we.
~Ling• O, 401~1 10111 ,.daca 001 4t 11110444 NOVIO 0400004,4 10 dm lose 14 ■ 04.0.1 7. LoYir14 La Sha 'luye Ify ryncabbrob eng•ITIOCT C.4~{ Dna." 04 1111,1 m1140•40,.
br1•4401- ■41,4
4 for by,llys ormowy ',Mulos yo to Sa 55413 2 by) orinightt 0,1.444. mono outio14,14
Tabla 6. Spring-Loadsd Type 630R Reliof Valva Pressure Limits

High-Prasaurs RO** Valve
Cieseription Lerw-Presauts Rtsiief Valva
Rellef Preaaure Setting Plus
Maximum Altowebis Rabat Rallar Pressure Setting Plus
Maximum AllowabIe Buildup of
Maximum AllowabIro Buildup of
(Inlet) Prassure, 250 psig 117 bar)
Puig (Bar) 25 puig (1.7 bar)
Maximum Emargancy 550 (38.0)

75 (5.2)
Inlet (Casing)
Preasurs• . Psig (Bar) 75 to 175 150 to 250
20 to 35 27 to 50 30 to 70 50 to 95
3 to 8 8 to 17 15 to 22
Relief (Inlet) Preature Settings. (0.2 to 0.5) (0.4 to 1.1) (1.0 to 1.5) (1.4 to 2.4) (1.9 to 3.51 (2.0 to 4.8) (3.5 to 8.5) (5.2 to 12.1) 110.4 to 17.3)
Psig (Bar) and Spring 1J1469 OW0191 OW0190 0Y0684 1.11489
OW0192 OW0191 OW0190 0Y0684
27022 27022 000A2 27142
Parí Number 27022 27022 000A2 27142
27022
0,44441,4•404‘814 .44 50,14 1110 OCCIN rf

orssowe esemeda the» vw u**.
•1-4*X*94 0, 04,41)e9
lief Valva Pressure Limita

1alif0 J. r o 11..••••• y .
111011•PRESSURE RELIEF VALVE

LOW•PlIESSUPIE RELIEF VALVE
LOADINO REGULATON TYPE Type 47 Type 130111
Typo 67 I
Rélief Pressurs Setting Plus Maximum
Reliad Pressure Setting Plus Maximum
Maximum AliCrwable Inlet Allowable Buildup of 250 asig 117 Bar)
Pressure to Ra1ief Valva AllowobIs Buildup of 25 paig (1.7 Sart
Maximum Emergency InIst 580 (38.0) 550 (38.0)

75 (5.2)
(Casing) Pressure* of Relisf
Valva. Puig (Bar)
Maximum Allowabli inlet 250 (17.3) 550 (38.0)1
Pringue* to Loadinq Regulen«
75 (5,21t
Psig (Bar)
50 to 100 100 to 225
10 to 20 (0.7 to 1.4) o<
Rabat Pressure Scrring6. (3.5 to 8.9) (8.9 to 15.5)
20 lo 50 (1.4 to 3.5)
Psig (Bar)
Maximum Emergency Outiet 250 (17.3)
75 15.2): 110 (7.8)
(Caiing) Prassurs• of
Loading Raguiator. Puig (Bar)
1 l,")ted lo tb.@ w)11,0 of ~muto emonbency ‹)«brig prbseure st 71011 5305.
Orlobbét• excmade ~u ...fa.
•"."9. '7"' 7•07.117 G7 9,...re-coma...1 paro 1105 eccur 7
t Lo,reb te tinly vb)),. by 110511111 wwe1gw,c-, ,r)les pm"). el ,a+)el ...Ny..
4
,,et3oserie4
Some pressure ratings are dependent upon the actual

WARNING outlet pressure settings being usad. For example, with a
Type 630 regulator, outlet pressure must not exceed the
Overpressuring any portion of this equipment setting by more than 20 psig (1.4 bar) for low pressure
may cause damage to regulator parte, leaks in constructions or 200 psig (14 bar) for high-pressure
the regulator, or personal injury due to bursting constructions, or damage to intemal regulator parta may
of pressure-containing parta or explosion of occur. However, with some higher pressure rangos, the
accumulated gas. setting plus 20 psig (1.4 bar) or 200 psig (14 bar) exceeds
the maximum emergency outlet (casing) pressure. Before
To avoid overpressure, provide an appropriate increasing the setting, refer to tablee 3 through 7 (as
overpressure protection device to ensure that appropriate). Review the pressure limita for the spring
nona of the limits listad in tablas 3 through 7 range being usad, and be certain that the new pressure
will be exceeded. setting wiil not result in en overpressure condition. Always
use a pressure gauge to monitor pressure when making
Regulator or relief valva operation below the limits adjustments.
specified in tablee 3 through 7 does not preclude the
possibility of damage from externel sources or from debris
in the gas line. Inspect the regulator for damage after any
overpressure condition.
Adjusting Spring-Loaded Regulators and
Relief Vaives
Lobeen the locknut (key 2, figures 5 and 7) stop the spring
Loading Regulator Supply Pressure case. While monitoring the pressure, rotate the adjusting
Use a alean, dry gas as supply pressure for the loading screw (key 1, figures 5 and 7) clockwise to increase set
regulator of pressure-loaded regutators or relief valves. pressure or counterclockwise to decrease it. When the unit
Connect the supply to the 1 /4-inch NPT inlet connection of is regulating or relieving pressure at the desired value,
the loading regulator. The supply pressure may be obtained tighten the locknut.
from the upstream piping, but be certain adequate over-
pressure protection is provided for the loading regulator
and for the spring cate of the main regulator or relief valva.
Adjusting Pressure-Loaded Regulators
and Relief Vaives
Loosen the locknut on the loading regulator spring case.
While monitoring gas pressure, rotate the loading regulator
STARTUP adjusting screw clockwise to increase set pressure or
counterclockwise to decrease it. When the unit is
regulating or relieving pressure at the desired value, tighten
Starting up the unit consista of turning on supply pressure the locknut on the loading regulator.
to the loading regulator for pressure-loaded units, and for
all units, opening the upstream block valva, introducing gas
pressure, and checking (alto adjusting, if necessary) the set
pressure. Use gauges to monitor pressures during startup.
SHUTDOWN
The range of alloweble pressure settings is marked on the
nameplate. If a premura setting beyond the nameplate
range le required, substituta an appropriate spring selected Siowly clase the upstream block valva. For pressure-loaded
from tabie 9. Select a loading regulator spring from the constructions, shut off supply pressure to the loading
appropriate loading regulator literatura. Be aura to chango regulator.
the nameplate to indicate the new presaure range.
WARNING PRINCIPLE OF OPERATION

To avoid the consequences of over-tightening
the spring in spring-loaded regulator or relief This section describes the operation of the Type 630
valves, consult tabla 8 and replace the adjusting regulator and the Type 630R relief valva with spring
screw with one of the correct Iength when loading. The pressure-loaded constructions opereta the
replacing the spring. same way except that force on the top of the diaphragm is
fr
630Séries
PRISSUNII iNUT SSSSS 1011
OUTUT PRESSUNI
n iOUTIET PRES310111
Figure 3. Type 630 Regulator Sectionat View valvt rtva

Figure 4. Type 630k Relief Va/ve Sectional View
pressure from a loading regulator, rather than a spring. Set
pressure is changad with an adjusting screw on the loading
regulator rather than on the main regulator or relief valve. WARNING
The Type 830R relief valve uses a light spring for added
stability. To avoid personal injury or equipment darnage,
isolate the regulator or relief valva from the
pressure system and release sil pressure before
Type 630 Regulators perforrning maintenance.
Retar to figure 3. In the regulator construction, outlet
pressure registers beneath the diaphragm. As long as the fi' the loading regulator of pressure-loaded constructions
outlet pressure is leas than the set pressure, spring force on requires maintenance, disconnect the supply pressure line
the diaphragm causes the levar to hold the vallé. opon. (and bleed orifica vent line if one is present) and unscrew
When the outlet pressure exceeds the set pressure, the the loading regulator from its mounting nipple. Refer to the
diaphragm moves to compresa the spring and the lever separata 67 Series or Types 1301 F and 1301G instruction
closes the valva until the outlet pressure retums to set manual for maintenance information.
pressure.
Except where indicated. key numbers in the foliowing
procedures are shown in figure 5 for spring-loaded Type
Type 630R Relief Vaives 630 regulator, in figure 6 for pressure-loaded Type 630
regulator, in figure 7 for spring-loaded Type 630R relief
Refer to figure 4. In the relief valva construction, inlet
valva and in figure 8 for pressure-loaded Type 630R relief
pressure registe, beneath the diaphragm. As long as the
valva.
inlet pressure is les* than the set pressure, spring force
causes the levar to hoid the valve closed. When the inlet
pressure exceeds the set pressure, the diaphragm moves to Replacing Seat Ring, Valve Disc, and
compresa the swing and the layer opena the valva allowing Lever
inlet pressure to bleed into the downstream line or to
atmoaphere until the inlet pressure retums to set pressure.
Note
With some piping systems it may be possible to

omit step 1 below by removing four cap screws
(key 17) and spreading the body (key 23) and
MAINTENANCE inlet adaptor (key 18) far enough apart to allow
removel of the seas ring (key 20) and Type 630
valve disc (key 21. figures 5 and 8) or the seat
Paris are subject to normal wear and must be inspected and
replaced as necessary. Frequency of inspaction dependa ring (key 20) and the Type 630R valva seat 0-
ring (key 37, figures 7 and 8).
upon severity of service conditions.
e
630 g•fiZDS
9. Be certain the lever (key 14) engages the valva carrier.

CAUTION
If step 1 is omitted and the body and inlet 10. Secure the diaphragm adaptar (key 1 3) to the body
adaptor are separated, take cara to avoid (key 23). Fit the adapto( (key 18) to the body (key 23) and
pinching fingen between the body and the install and tighten the four cap screws (key 1 7).
inlet adaptar.
1. Disconnect piping from inlet adaptar (key 1 8). Remove

four cap screws (key 1 7) and adaptar.
Replacing the Diaphragm
2. Remove seat ring (key 20) and gaskets (key 19). 1. Relieve spring compresaion as follows:
3. To remove Type 630 valva disc (key 21, figures 5 and 6) e. For spring-loaded constructions, loasen locknut
or Type 630R valva seat 0-ring (key 37, figures 7 and 8), (key 2, figures 5 and 7). Turn the adjusting screw (key 1,
first disconnect remate vent ;Jipe (if orle is usad). For figures 5 and 7) counterclockwise until spring compression
pressure-loaded constructions, disconnect loading- is relieved.
regulator supply line.
b. For pressure-ioaded Type 630R relief valvas (and
4. Unscrew the two cap screws that secura diaphragm for pressure-loaded Type 630 reguletors that have been
adaptor (key 13) to body (key 23); remove diaphragm furni'shed with a spring), turn cap screw (key 1, figure 8)
adaptar and attached spring case (key 3). counterclockwise until spring compresaion is relieved.
5. If it is necessary to replace the levar (kay 14), drive out

the pin (key 1 5) and sude the levar out of the diaphragm 2. Oisconnect remota vent line (if one la present).
adaptar. When replacing the levar, maks sure the slot
engages the connector assembly (key 1 2) and replica the
3. For pressure-loaded constructions, disconnect the
pin. supply pressure line from the loading regulator (kay 28,
figure 9).
6. Remove valva carrier assembly (key 22) from body.
7. To replace seating surface: 4. Remove spring case (key 3) by unscrewing cap screws
and nuts (keya 9, 10, and 30).
a. For Type 630, use a 3/4-inch socket wrench to
remove and re-install valva disc and holder assembly (key
5. Remove diaphragm (key 11) and attached parta from
21, figure 5 and 6).
the levar (key 14),
b. For Type 830R, unscrew machina screw (key 36,
figures 7 and 8) and remove 0-ring washer and 0-ring (keys 6. Unscrew cap screw (key 6) from connector head
32 and 37, figures 7 and 8) from 0-ring holder (key 21, assembly (key 12) and disassemble the diaphragm
figures 7 and 8). When reassembling, apply a good-quality assembly.
gasket shellac to the machina screw thread.
8. Use new seat ring gaskets (key 19) and body gasket 7. (natal' new diaphragm. Note that low-presaure
(key 16) when reassembling. Insert valve carrier assembly constructions use a diaphragm plata (key 8, figure 5) on the
(key 22) finto the body before re-instailing the diaphregm spring caes sida of the diaphragm. Low-pressure, pressure-
adaptar. loaded conatructiona use e diaphragm piste on each sida of
the diaphragm and a diaphragm plata gasket (key 38, figure
8) with each plato. (natal( new gaskets when replacing
Note
diaphregm.
The spring case (key 3) must point away from
the adaptar (key 1 8) on Type 630 regulators es 8. When reassembling, be certain that the diaphragm
shown in figures 5 and 8. On Type 630R relief connector is engaged in the levar.
valvas, the spring case must faca the same
direction as the adaptar (key 1 8) as shown in
figures 7 and 8. 9. To ensure proper slack in the diaphragm:
7
630 Series
a. For constructions using a spring, tighten the spring

case cap screws finger-tight only. Comprase the spring PARTS ORDERING
slightly with the adjusting screw (or cap screw for pressure-
loaded constructions); Chen complete the tightening of
spring case cap screws and nuts.
b. For constructions without a spring, tighten spring

When corresponding with Fichar representativa or the
case cap screws fingar•tight only. Remove cap screw (key
factory concerning this unit, state the type reurnber and all
1, figure 6). Insert a rod in the spring case and push on the
diaphragm assembly to take up the slack; then complete other pertinent information on the nameplate. Specify the
the tightening of spring case cap screws. Re-insta)) cap eleven character pan number when ordering new parte
screw (key 1, figure 6) in spring case. from the following parte list.
PARTS LIST
Key Dttecriptiorl Pert Number
1 Adiusting Screw, steel Sea tabla 8

2 He. Nut, Cd pl otee( (non. reci'd for
prsaeure-ioeded) 14.3524 24122
3 Spring Case
tow•pressure
Cast ;ron 3C7809 19042
Steel 3N6981 22012
High-pressuro
Cast (ron 3C7808 19042
Stesi 3P46983 22012
4 Upp.r Spring Sest, zinc
Typo 830 pressure-loaded (nono reo'd)
T'O. 830 Et 830R apnng 'ceded Et
Typo 630R presaure-foaded
Pres-sur. ring. to 275 PaI9
(19 bar) OW0193 44022
preasure rango over 275 P 119
(19 bar) 1K3711 44022
5 Spring, steel Se. tibie 9

6 Ceo Screw, pl ateo( Figure 5. Spring•Loaded Typo 630 Regulator—Low-Pressure Cerrstruction
roes 630 Et 530R low-pre.sus.
orsiisure !ceded 1 81 363 24052
Description Per. Numb.r Key Description Pert Nurnber
Ali °there 1 R81 76 99012 Key
7 Lower Spring Seat 17 Cap Screw, reel (4 net)
11* Disphregm, neopreno
Low-presaure, l" bah? /A9359 24052
1..Pw-pressune OW0200 02192
'cosi OW0203 24102 143535 24052
High-preesure OW0199 02192 2•• body
High-pressure. zinc 18 Inlet Adaptar, ates!
Pressure range to 275 peig 12 Connettor Hm( Asa'y
Pressuro-loadad. low-preseure Only 1" NPT 1P4798 23022
(19 bar) OW0201 44022 2'• NPT 1 P4799 23022
Aluminum trim 1C3000 X0012
Presaure renga over 276 Pala Inkrt Body Gasket (2 reo'd)
SST tnm 1 C3000 X0022 19
(19 bar) 11(3710 44022 Copper, for breas
Diaphregm Mete, Cd pl ate& Al others
8 1 P8455 00042 trtm CW0184 15042
Alurninum trim
Low-pressure onty Asbestos, for SST
SST trfm 1 P8485 000132
Spnng-loaded mm OW0184 04022
(1 reci'd) OW0202 25072 Seat Ring
13 Disphragm Adaptar 20
Preisure-foaded Typo 630
OW0202 25072 Low-pressure
(2 rocrd) Brasa
Cast iron OW0197 19012
Stasi 2N6985 22012 1/8" (3.2 mm)
9 Cap Screw, Cd pl steel port die 020400 14012
143526 24052 High-pressure
Std (2 req'd) 3/15- (4.8 mm)
Cast iran OW0198 19012
Wire seal port die 182195 1401 2
Stsel 2N8987 22012
(1 rocíe() 14.3528 24052
14 Lever Aaa'y 1/4" (5,4 mm)
(1 reci'd) 184191 24062 OW0183 14012
low-pressure 1 82891 00042 port dio
10 Cap Screw, pi ateo( 3/8- (9.5 mm)
High•presaurs 1 82890 0004.2
Low-praseure pon Pm OW0182 14012
I5 Pin, SST OW0188 351 72
(10 recy'd) 1A3525 24052
16 Geeket. asb/nithie OVVOI 87 04022 1/2- (12.7 mm)
High•preuure pon die OW0181 14012
(4 req'cl) 143525 24052
- *.t0TmHlod .p.re pan.

8
630 Series
,fal .•••■■■•■•(•,.W.M..............■
"11
)
It II?
III
'I
I I 104111Imin1ouvneanr
ICIPM7
n..
10' "
111 01VI1W
Figur• 6. Spring-Looded Typo 630 Regulator—High-Pressurs Construction
Key Oeseription Pera Number Key Deeeription Pert Nurnber Kay DeetriotIon Pan Number
20 Seat Ring (Continuad) 23 Body 38 Machine Scrow

1" NPT, cosí iron Type 630R only
SST
wr/brau pitot Brasa 1.46826 18992
1/8" (3.2 mm)
tube OW0209 00042 SST 103364 35042
port dia 1 K4166 35032
w/SST pitot 37' 0-Ring
3/16" (4.8 mm)
tuba OW0209 X0012 Type 830R only
POR dia 11(4165 35032
1" NPT. steel Nitrito 102888 06992
1/4" (6.4 mm)
w/breas pitot TFE 1F5819 06522
port dia 1 1(4164 35032
tul» 2N8990 00042 38' Gesket. asbestos (2 recrel)
318- (9.5 mm)
w/SST pitot For low-preasure. pressure-loaded
port die 11(4163 35032
tube 2N6999 X0012 °n'y 1 81 922 04022
1/2" (12.7 mm)
2" NPT, casi iron OW0215 19012 39' Gasket. copo«
port die 11(4182 35032
2" NPT, steei 2N6991 22012 For pressure loaded
Type 830R
only 0Y0089 15042
Brees. 1/2" (12.7 mm)
port dia 1137350 14012 27 Vent May (nona req'd for preseure-
loeded) Y602X1 -Al2 44)* Gsaket, copoar asbestos
SST. 1/2" (12.7 mm)
28 Loading Regulator (for pressure-loaded For pressure-ioaded
pon die 187350 35032
only) only 1E2759 99212
21 Vatve Disc Aas'y Type 67. 6714, 1301F or
Type 630 only 13012
Brsea/nitrile 184600 00042 30 Hex Nut, Cd pl steei Neto
SST/nitrile 184500 00082 Low-preseunii
1 P7361 X0012 (1 0 r•t14) 143527 24122
Bress/poiyurethene Key nos. 47. 48 Er 49 are for
SST/polyurethene 1P7361 000A2 High-pressure
pressursIoecled units only.
(4 req'd) 1A3527 24122
Brasa/nylon 1C1880 000A2
SST/nylon 1C1860 00082 31 Cap Screvr. pl «est (2 req'd)
47 Pioe Niople. zinc pl gelvenized
(not shown) 143411 24052
Brase/TFE I C I 860 000C2 steel 182188 28232
SST/TFE 1C1880 00002 44 Street Elbovo, mailesbie ron
21 0•Ring Holder 32 0-Ring \Weber (For 630R onty)
High preasune units
Breas 103359 14012
Typo 630R only 149132 21992
103360 14012 SST 103359 35072
Brasa 49 31eed Orifico MeV
SST 103380 35032 33 Plug. pl tta.l (not shown)
Lavo presaure
22 Velve Carrier For 2 - NPT bodiee 3.20 psig (0.2 to 1.4 bar) loading
OW0186 14022 onty 108293 28982
Brasa regulating ranga 11(8845 X0012
SST OW0186 35032 34 Nameplete, aluminum
20.100 paig (1.4 to 6.9 bar) loading
Type 830 1F7498 11032
regulator rengo 11(8844 X0012
Type 630R 2145495 X012
High pressurs 11(8843 X0012
35 Drive Screw, SST
(4 req'd) 1A3682 28982
9
'I10cO.nonMOW apare ove.
630 Series
g 9
12
\ \
1101 V1IIVE
:H.
Figure 7. Swing-Loador' Typo 630R Rail« Valve—High-Pressure Construction
MI •
Figure 8. Pressure-Loadod Typo 630R RO« Valvo—Low-Pressure Construction
10
630 Series
LOADING 1111FOULAT011
SUP111.1 CONNICTION
111,11111
1.01.0111111111113ULAT001.1
■■2■1.11" - $LIED
48
28
.49
..1111.•
••••■•
Figure 9. Exterior View of Pressure-Loétled Typo 630 Regulator—Low-Pressure Construction
rabie 8. Key 1, Adjusting Screw, Steel

ADJUS11NG CORVO/ LENOTH OF
SPRING ADJUSTING SCREW PART NUNISEIII THREADED PORTION
TUPE PART NUMSER
PART NUMSER (WIRE SEM) In. ~I
■
0NV0192 27022 1 A2791 28982 1R8299 28992 4 102
OW0191 27022 182120 28982 1R8300 28992 3.1/2 89
OW0190 27022 1A5005 28982 1R8085 28992 3 76
830 0Y0864 00042 146005 28982 188085 28992 3 78
1A5005 28982 188085 28992 3 78
1J1489 27142
1K3709 27082 145005 28982 18E1085 28992 3 76
Nonet 1C1162 24092 •• • 7/8 22
OW0192 27022 142791 289/12 188299 28992 4 102
OW0191 27022 182120 28982 188300 28992 3.1/2 89
OW0190 27022 145005 28982 1 88085 28992 3 78
83OR 103358 28982 1R8301 28992 3.1/4 83
0Y0664 00()42
1 J 1489 27142 103366 28982 1R8301 28992 3-1/4 83
OW0192 27022 t 103590 24492 ... 2.3/16 56
1 /41~4~.1.cteded ~mucoso.
11
630 Series
rabie 9 Key 5, Regulator Spring, Steel
Outlel (or Relief) Prereaues Spring Pon Swing Color

Type Number Code
Sstting, Paig (Bar)
i. Red Stripa
3 to 10 0.2 to 0.7) OW0192 27022
8 to 20 ;0.8 te 1.4) OW0191 27022 My, Drab
Low-Priesture OW0190 27022 Zinc Plata
17 to 30 (1.2 to 2.0)
27 to 40 (1.9 to 2.8) 0Y0884 00042 Green Stripa
Spring.i.oaded 27 to 50 (1.9 to 3.5) OW0192 27022 Red Stripa
TYPO, 630 48 to 95 (3.2 to 6.8) OW0191 27022 01iye Oral,
90 to 1 50 (6.2 to 10.3) OW0190 27022 Zinc Plata
High.Preliure 150 to 200 (10.3 to 13.8) OY0884 00042 Green Strip*
200 to 275 (13.8 to 18.9) 1.11489 27142 Nue Stripa
275 to 500 (18.9 to 34.5) 1K3709 27082 Vallo'« Strip.
.
3 to 8 (0.2 to 0.5) OW01 92 27022 Red Stripa
6 to 17 (0.4 to 1.1) OW0191 27022 Oliva Strip,
Low-Pressure 15 to 22 (1.0 to 1.5) OW0190 27022 Zinc Plata
20 to 35 (1.4 to 2.4) 0Y0864 00042 Green Strip*
Spring•Laaded 27 to 50 (1.9 to 3.5) 1J1469 27142 Nue Stripa
Type 630R Oliva Drab
30 to 70 (2.0 to 4.8) OW0191 27022
50 to 95 (3.5 to 8.5) OW0190 27022 Zinc Plata
Hion•Preseure 0Y0884 00042 Green Strip.
75 to 175 (5.2 to 12.1)
150 te 250;10.4 to 17.3) 1J1489 27142 Nue Strip*
10 to 20 or 20 to 50 Red Strip*
Low•Pressuna OVV0192 27022
Presaure-Loaded (0.2 to 1.4) or ( 1 .4 to 3.5)
Type 630111 50 to 100 or 100 to 225
Red Strip*
Hiph-Pressure OW0192 27022
(3.5 to 8.91 or (6.9 to 15.5)
iiivirms trua neennatcn is alimentad n ~rasar. ano beeweb ro be ~ale Feria Cerro* cose mercharraberra ',fresa or any «net mane/ .Mn nitSpeCt ro the Prablocre rey asa recommer*
sataaectory re*Jel MY^ rQerC1 LCCrIUMI eternIMM, NOthonconfh~lnrnion dation to use ary [recua a a-ccmsa n coroct wici any cerera. Fané Carros ~es re 'qt
s 'o Do cOnstruee asa voirinly Or guSrintelt • x0reSs or nnaidsrv mg ~tory. Wal wyncrit 'nace. 2ner a ~eme 1w 0•49-4 or scece~e cr the predi-CM de1CINI0 Meren
For in lo rMatiOn write:
nsHER*) Fisher Controls P O 510x 190. MeteneIrtOwn, loyee 50158. U S A.

or Brenchtey House. kleidatone. Kern ME 14 1 U O . Engiand
PV-94129B
Mur ph Revised 04-00
Catalog Section 55
(D0-02-0126)
Pneumatic Valves for Fuel Gas Shutoff

Models M2582-P
and M5180-P
■Pneumatically Open and Shut Off Fuel Gas
Automatically or Semi-automatically
■Pneumatic Control Pressure Can Be
Air, Gas or Oil
■Models for 2 in. or 1 in. (51 mm or
25 mm) Fuel Gas Lines
Model M2582-P
Description bar] and fully opens the seat at 3 psi (21 kPa) Control Pressure (Maximum):
The M2582-P and M5180-P are pneumatical- [.21 bar]. The valve can be manually opened M2582-P: 75 psi (517 kPa) [5.17 bar]
ly controlled fuel shut-off valves that open with lever and latched against inlet pressure M5180-P: 80 psig (552 kPa) [5.52 bar]
and close automatically or semi-automatical- of 100 psi (689 kPa) [6.89 bar]. The latch will
ly. The pneumatic control pressure can be air, release after pilot pressure reaches 2.5 psi (17
oil or gas. A manual lever aids in opening the kPa) [.17 bar].
valve when control pressure is insufficient. A How to Order
gas escape vent, when properly vented and Specifications To order, use the diagram below.
maintained, releases trapped gas from the Valve Body: Sandcast aluminum
valve after shutoff. (alodined for corrosion resistance).
Optional steel body available on M5180-P
Basic Operation models only (see How to Order). Model
Automatic: As the control pressure/vacuum M2582-P
increases the valve will open. When the control Valve Seat: Buna-N M5180-P
pressurelvacuum decreases, the valve will close. Valve Inlet Pressure (Maximum):
Semi-Automatic: If the control pressure/vacuum M2582-P: 80 psi (552 kPa) [5.52 bar] Body
is too low and the valve does not open automat- M5180-P: 100 psi (689 kPa) [6.89 bar] Blank = Aluminum
ically, it can be opened manually by lifting the 2 = Steel (applies to M5180-P)
built-in lever arm and setting the latch. The Parts Exposed to Gas Line Flow:
latch resets automatically when control pressure M2582-P:
rises enough to release it. • Aluminum
M2582-P is for 1 in. (25 mm) gas fines. It auto- • Buna-N
matically opens at 2 psi (14 kPa) [.14 bar] and • 302, 303, and 17-7 PH stainless steel Warranty
fully opens the seat at 3 psi (21 kPa) [.21 bar]. M5180-P: A two-year limited warranty on materials and
The valve can be manually opened with the • Aluminum (Steel optional) workmanship is given with this Murphy
lever and latch against inlet pressure of 80 psi • Buna-N product. Details are available on request and
(552 kPa) [5.52 bar]. The latch will release after • 302, 303, 304, and 416 stainless steel are packed with each unit.
pilot pressure reaches 2.5 psi (17 kPa) [.17 bar]. Control Diaphragm: Flexweave polyester
The M5180-P is for 2 in. (52 mm) gas lines. fabric and Buna-N elastomer.
It automatically opens at 2 psi (14 kPa) [.14
rP
M2582-P Dimensions M2582-P Flow
ea
Characteristics rA" ,e1
.....-
,..., rsi
,....
.....1 ....; -1 -.N
1/4 in. (6 mm) tube Laboratory Test --, ...„
ei, ■tr
....,
4,
:r •Ir
connection; control CZ .kg A
4« co -.., ,..
ezs Z.
... ...n,j. qa- 45 ...' O
st\f
_
pressure 3 psi (21 kPa) T.. ,r2 ■._ ‘....
s.; .i 15 41'
[.21 bar] minimum, "i 0 li 41. IP IP
° O C/.. m. g..
75 psi (517 kPa) NT .. 4, .5'. O
".■ % O
10.0
Latch Arm (see NOTE) [5.17 bar] maximum. [254.0]
9.0
^ [228.6]
en o 8.0
[203.2]
ts -15
R i
BreatherNent 7.0
1/16 in. (2 mm 12 [177.8]
-o .E
8.0 t
[152,41 1.
1 NPT
(2 places) E 5.0
[127.0] 1
6-9/16 in.
1/4 NPT. (167 mm)
8y 4.0
[101.6]
Vent and 3
3.0
Plug
3-3/32 in. 1 fA
[76.2]
-0-(79 mm) [50.81

-41- 5-1/2 in. (140 mm)
5.
1.0
[25.4]
NOTE: Thumb operated opening latch (2.5 psi [17 kPa]
[.17 bar] required to release cocking latch) 0 250 510 750 1000 1250 1500 1750 2000 2250 2503 2750 3000
[7.08] [14.16] (21.24] [28.32] (35.40] [42.48] [4956] [56.64] (63.72] [70.80] [77.88] [84.96]
Standard cubic feet per hour

Cubic meters per hour in brackets
M5180-P Dimensions Shipping Weights

M2582-P: 5 lbs 10 oz (2.55 kg).
Latch Arm (see NOTE 2)
M5180-P: 14 lbs 9 oz (6.61 kg).
With steel body option "2"; 25 lbs (11.34 kg).
t
Breather Vent 10-7/16 in. (265 mm) 6-1/8 in. Shipping Dimensions
(see NOTE 1) (156 mm)
M2582-P: 8-1/4 x 8-1/4 x 7-1/2 in.
1/4 in. (6 mm)
connection;
(210 x 210 x 191 mm).
2 NPT
(2 places) control pressure M5180-P: 12-1/4 x 12-1/4 x 9-3/4 in.
3 psi (21 kPa) (311 x 311 x248 mm).
(.21 bar] minimum,
BO psi (552 kPa)
[5.52 bar] max. Service Parts
(see NOTE 1) 4-3/8 in.
(111 mm)
Specify part number when ordering. M2582P m5180p
Vent and Plug
1/2 NPT Handle and Latch Kit 55000148 55000154
4-1/4 in. Stem and Seat Kit 55000147 55000135

9 3/8 in (238 mm)
(108 mm) Top Works Complete Valve Less Body & Vent 55000150 55000155
Vent Bushing Assembly 55000143 55000132
NOTE 1: Control pressure connection fitting and breather vent fitting can be swapped to convert to vacuum control.
NOTE 2: Thumb operated opening latch (2.5 psi [17 kPa] (.17 bar] required to release cocking latch). Diaphragm Assembly 55000184 55000153
Pilot Diaphragm 00007908 55050420
In order to consistently bring you the híghest quality, full featured products, we reserve the right to change our specifications and designs at any time.
FRANK W. MURPHY MANUFACTURER P.O. Box 470248; Tuba, Oklahoma 74147; USA tel. (918) 627-3550 fax (918) 664-6146 e-mail sales@fwmurphy.com http://www.fwmurphy.com
FRANK W. MURPHY MFR. MURPHY DE MEXICO, S.A. Df C.V. MURPHY SWITCH OF CALIFORNIA
CONTROL SYSTEMS & SERVICES DIVISION Bhtd. Antonio Rocha Cordero 300, Fracción del Aguaje 41343 12th Street West
*murph P.O. Box 1819; Rosenberg, Texas 77471; USA San Luis Potosí, S.LP.; México 78384
tel. +52-48-206264 fax +52-48-206336
Pa]mdale, California 93551-1442; USA
tel. (661) 272-4700 fax (661) 947-7570
tel. (281) 342-0297 fax (281) 341-6006
e-mail sales@fwmurphy.com e-mail ventasmex@murphymex.com.mx e-mail sales@murphyswitch.com
http://wvnv.murphyswitch.com
FRANK W. MURPHY, LTD. FRANK W. MURPHY PTL, LTD.
Church Rd.; laverstock, Salisbury SA1 101; U.K. No. 2 Tuas South Street 2, MACQUARRIE CORPORATION
tel. +441722 410055 fax +441722 410088 Sprinters Bldg., #02-01/02 1620 Hume Highway;
e-mail sales@fwmurphy.co.uk Singapore 638042 Campbellfield, Vic 3061; Australia
USA-ISO 9801 FM 2822 http://vnimármurphy.co.uk tel. +65663-1398 fax +65 863-0208 tel. +61 3 9358-5555 fax +61 3 9358-5558
01(-1S0 9002 FM 29422 e-mail fvensales@fwmurphy.consg e-mail murphy@macguarrie.can.au
FRANK W. MURPHY FRANCE
Printed in U.S.A. tel. +33 1 30 762626 fax +33 1 30 763989
Gc) m ies
■ Extended Seat Life ■ Soft Seat Tie Iness

■ Crisp "Pop" Action ■ Full Nozzle Capacities
■ Premiurn Construction Details
MERCER VALVE CO.

M 7211 Northwest 3rd Street • Oklahoma City, Oklahoma 73127 • (405) 495-6533
FAX 405-495-8728
SPECIFICATIONS
BASIC VALVE SIZE 1" NPT 2" NPT
Inlet Valve Size 1/4" FNPT 11/2" MNPT

1" MNPT 2" MNPT
Outlet Size 1" FNPT 2" FNPT
Orífice Diameter .520 in. .775 in.
Orífice Area .212 sq. in .472 sq.
Pressure Ranges 15-2500 PSI 15-2000 PSI
Temp. Ranges
Standard —20°F to 400°F
Extended —40°F + 600°F
ASME "slope" (90%) 3.10 7.21
Flow Coefficient "K" (90%) .80 83
Weight 4.5 lbs. 10.0 lbs.
PARTS AND MATERIALS
Itero No. Part Name Standard Materials Options

Carbon Stainless
Steel Steel
1" NPT
Basic Size
Base
Seal
3 Body WCB Carbon

Steel
Spring Stainless
Steel
1011$
Guide Carbon Stainless
Bushing Steel Steel
"O" Ring Buna N Viton
10
Viton 4'/2
11 "0" Ring Buna N
(not shown)
2" NPT
—234-1
Basic Size
INTRODUC'TIQM
Mercer Valve 8I00 Series Safety Relief Valves are the rSlzte of the Ad in soft seat, high flow
rate, pressure releiving devices. The field-proven Viton soft sed? is coupled with a new, unique disk
type valve design (Patent Issued). Expected seat life is hundrecls of Full length guiding of iow
late' set pressure springs insures acctircrte, repeatable relief action.
The Valve is well suited for all industrial air or gas relief applications, including compressors
separators, refinery application, transmission and gathering unes, gas production units, heater
treaters, scrubbers, and other production processes.
All 81 Series Valves are built in accordance with the requirements of the ASME Boiler and
Pressure Vessel Code. Capacity ratings were established by testng performed at the Natio nal Board
of Boiler and Pressure Vessel Inspectors, Columbus, Ohio.
PRODUCT NUMBERING SYSTEM

A specific 81 series valve is described by a 10 digit product numbering code as follows:
BODY TYPE &

°ATICE MATERIAL
SDrE 2 - Steel Cast.
2 - 1/2' soft seat Teflon WCB BLOWDOWN
3 - 1/2' soft seat Buna N 3 - Stnls. Sti. O - Extended 30%
4 - 1/2' soft wat Vtton fabrioated 1 - Nominal 25%
7 - 3/4' soft wat Teflon 4- 2 - Reduced Value
8 - 3/4' soft seca Viten cast. (Consult Fcrctory)
5 - Ductle Loe
81
CaP Spling Code

Type (asanned by
Inlet Sub Assembly
1 - Clcused MERCER VALVE)
Bade Vals. 1 - 3/4' MNPT nuld di.
top
Sise & Type 2 - 3/4' FNPT atad sti.
2 - Open
1 • l• acrewed 3 - 3/4' FNPT strde. d.
bit levet
2 - 2' sorewed 4 - 1' MNPT rutki id
3 • Packad
5 - 1' MNPT *da id
lift
6 - 1 1/2' MNPT =Id ad
leyes
7 - 1 1 (2- MNPT gola. stL
8. 2' MNPT =Id sd.
9 - 2' MNPT atril& a&
ORDERING
To arder a Safety Relief Valve, a 10 digit product number must be selected plus designation of a
set pressure and any special features such as "Nace Trim".
• Basic valve size • Cap type
• Orifice size • Blowdown specification
• Inlet sub assernbly & material • Set pressure
• Body type and material • Service temperature
SAFETY RELIEF VALVE SIZING WHERE:
Ww1bihr welqht iiow cilas. Çp
Saielv Re:e! rnay oe 1:zea by tzrrnuIa rcapacity ;han. whichever :he user A=effechve tiow a:e :n squaretr.ches. This ¡actor s caiculated from 904.: oí the
prez Instantaneous siope deterrn:ned by capacIry tests :cr,duzzed at the Ncrtionai Bcm.d.n
SIZINC.,57' 1.-CDFLMULA. Appenatx Secncr. VIII Dvstor. i of the ASMIE Botierar.d accord=ce with UG :31. SEchon 1It of the Code.
p se. Cede brescr:wes tne tcrrnu.a lar :apaz.res of znhces. These bas:z P=Iset pressure x I : piuz atmosphenc pressurel psta. Ti-.s 1s a 10c.. acration.
M..rna1eu.ar welont
,= KACP (EQ 1) T=obsoiute temperature at :r.letfT + 460t
WvIGr --"W Wib n
C..constar.: ter gas zr vacar wiitch :s atuncticr. CL :ct:c ci specti:c neats.
c.
5.z.pec1ited Condthons Q = KACP (EQ 2) yr...:i.ensity al gas m e:e zondirtorts. Th:s :s usually spec:i:eaat standar.: zi
SCFM w X 60 60*F and 14 7 psta. Jos., zu. it
K.■F:cw ericerts
Tabla Molecular Wt. oral Volaos of C for Gaseo
Gas Mol Wt. Cp/Cy C Gas Mol Wit. Cp/Cy C
Acery:ene 26 I 28 345 Hydrocr.Ionc Acta' 365 140 356
Arnmenla ¡7 I 33 351 Hydrocien SuIon:de 34 1 32 348

Mica 3ZEr-5:W:17 328
Benzene 78 : 10 327 Methcrne 16 30 346
.-arbor Dtcxide 1.28
Ch.onne 71 1.36 352 Natural Gas 10.61 :74 27 344
r reon 22 18 355 Prooane 14
1-lexane 1 08 324
AIR CAPACITIES NATURAL GAS CAPACITIES

SET 81-14000000 81- 28000000 81-14000000 81 -28000000
PRESSUHE 1/2- Orifice 3/4- Orifice W Orifice 3/4- Orifice
:5 (PSIG1 101 ( SCEMI 236 (SCFM :20 (SCFM) 280 • scFn
111111111111*...-:;.." -- c.-2.-- "•?..-..tr ---:-7 7-2---- T - --_ s_.-.. . -• ..''r:: -. - .."M':.-7-7.eij.i.itilin
•
25 132 308 163 379
iii.iiiKt.:,:71C4áii,......,,o ... .. •-,,- .1;-; -,:- -.. .: —: ..._-:"... ."."..-17:k.t..7.1.Z '1Z.C....‹;.-.1...11W.
50 216 503 269 626
,É.J
' -2.----:- „.. - -- --,;-... :._ ..-`r'- _-:':,-:.;_ li.75_ - :.7.11'1
100 387 899 481 :119
--- .. 1.-.27 :: - .1 ..27.. ;. 7'7'1
150 557 1296 693 :613
iiiiiiiit~ . -- ''-"' :..- 7 , _ .- • _ -- -.;',.. .. "rlin,: !..71-E.1--.....----.1 ' :1• 7- '
200 728 1692 906 2106
tli~. -- ', ..... . -
300 1069 2485 1330 3094
._ - . -....;_l_ .:- . ' .:, ...,,,.... ,-;-1..--
_ . ".
400 1410 3278 1755 4081
. ,.,_ ... ,..,
. - ...- ,, ..4,-
500 1751 4071 2197 5068
600 2092 4865 2604 6055

7-'111
700 2433 5658 3028 7042
Wigl#1.~::::=7::.:-.'',2.1 . _:-- -;,.7-- ..;:: .^.•;,...;-_, ' --- .
:::_ ..: ''- ' • ..--,-, "--1- • J.- - -- . 7.--.-.7...-'
acc 2774 6451 3452 8030
ligiiii iell . - _-F-1-.•:-. --,.::¡-.,=" ...?"-" -- -. - - '-:•'._ . • ' - _ :- -.'"•t.',
:::..- - • .,7-z...,- i
000 3456 8037 4301 10004
1 laD :-. - -.. • ~5111X211911ffilM94-_-.:— . - :-.;.1--.l- í. •,:.k...-::_l_.1 : _ •:...-.!.. . _....-.:-..,.,,_._ ._ . : - :
:250 4308 10020 5363 12472
150/... - - r ZiialiiiLirr" ....
'00#. - ÷'.':. _ .,:' ..niki :..-:.. L- ......-.._.-.P.."1 -
1750 6013 13985 7485 17408
11111211111 =Me 1=: 7"MIRMIE .__-- __. - V€1131:11~
.2250 7718 17951 3607 22344
: - ~ =-_.
1 -72;
3000 10273 23899 :2791 29748
TDI TURBOTVVIN
Engine Air Starters
INSTALLATION AND OPERATING INSTRUCTIONS

MODEMS T112E3[1-121 T106F/T112F, T11213[7121D
Pubücalion T1-702
Issued 16June1995
TDI TURBOTWIN
FROM TECH DEVELOPMENT INC
INSTALLATION & OPERATING MANUAL

FOR
MODELS TIO6FrT112F, T.112B/T121B, T112D/T121D
TURBINE STARTERS
USE WITH COMPRESSED AIR OR NATURAL GAS
TABLE OF CONTENTS LIST OF FIGURES
1.0 GENERAL INFORMATION 1. TURBOTWIN PART NUMBER LISTING

1.1 DESCRIPTION 2. MODEL T112B/T121B INSTALLATION DRAWING
1.2 PRODUCT IDENTIFICATION 3. MODEL TIO6FrI1 12F INSTALLATION DRAWING
1.3 PHYSICAL CHARACTERISTICS 4. MODEL T112D/T121D INSTALLATION DRAWING
1.4 PERFORMANCE (STD MESH)
5. MODEL T112D/T121D INSTALLATION DRAWING
2.0 INSTALLING THE STARTER (LONG MESH)
2.1 GENERAL 6. INERTIA DRIVE ASSEMBLY SPECIF1CATIONS
2.2 STARTER ORIENTATION 7. EXAMPLE NAMEPLATE
2.3 INERTIA DRIVE ASSEMBLY 8. DIRECTION OF ROTATION DEFIN1TION
_2.4 SUPPLY LINE 9. PERFORMANCE GRAPH MODEL T121B/T121D
5 INLET PRESSURE PORT 10. PERFORMANCE GRAPH MODEL T112F3/T112D
L.6 EXHAUST CONNECTION 11. PERFORMANCE GRAPH MODEL T112F
2.7 NATURAL GAS USAGE 12. PERFORMANCE GRAPH MODEL T106F
13. TYPICAL STARTER INSTALLATION - COMPRESSED
3.0 HARDWARE AND ACCESSORIES AIR
14. TYPICAL STARTER INSTALLATION - NATURAL GAS
4.0 STARTER OPERATION 15. INERTIA DRIVE PINION BACKLASH
4.1 BASIC OPERATION 16. EXHAUST ADAPTER RING INSTALLATION
4.2 MANUAL VALVE OPERATION 17. EXHAUST HARDWARE KITS
4.3 AUTOMATED START PANEL 18. ILLUSTRATED EXHAUST HARDWARE OPTIONS
19. INSTALLATION ACCESSORIES
5.0 PREVENTIVE MAINTENANCE
6.0 STARTER DISASSEMBLY AND REPAIR
7.0 OPERATOR'S TROUBLE SHOOTING GUIDE
8.0 TURBOTW1N WARRANTY
Publication T1-702
Issued 16 June 1995
TDI TURBOTWIN
1.0 GENERAL INFORMATION 1.1 DESCRIPTION
Figures 2, 3, 4 and 5 show the outline of the Tour basic

This manual provides instructions for the installation and
TURBOTWAtriodels of starters. AH models feature three
operation of the TDI TURBOTWIN Starters. If there are
basic subassemblies: a unique two stage turbine motor
questions not answered in this manual, please contact your
section, a planetary gearbox section and an inertia drive
TDI TURBOTWIN distributor or dealer for assistance. See
Appendix A for the listing of distributors by state. assembly.
The TURBOTWIN models are turbine driven starters with Compressed air or natural gas is used to power the
an inertially engaged starter drive. Depending on the starter TURBOTWIN through the inlet port. The air or gas is
model and engine installation, the TURBOTWIN starters expanded through the first nozzle or stators. The high
have applications ranging from 1000 CID (16 Liters) on velocity gas impinges on the first stage rotor to yield torque
diesel engines and up to 20000 CID (320 Liters) on gas to the gearbox. The gas is further expanded through the
second stage stators which impart additional torque to the
engines. The TURBOTWIN models are suited to operate
within a wide range of inlet pressures and ambient second stage rotor.
temperatures. Refer to Figure 1 for general specification
information. The engine size and parasitic loading will The two stage motor section features greater stall torque
determine the exact minimum pressure that will assure than a single stage turbine plus aerodynamic speed control.
This aerodynamic speed control helps protect the
reliable starting.
TURBOTWIN starter from damage caused by starter motor
over speed. In addition, a steel motor housing module and
The TURBOTWIN starters are designed for operation with
compressed air or natural gas; materials used are low-mass rotors provide fail-sate operation.
compatible with "sour" natural gas and marine
environments. Small amounts of foreign matter or liquid in All TURBOTWINS employ the same basic 7.5:1 ratio
the air stream will not adversely affect TURBOTWIN planetary gearbox. Reliability and part commonality are
starters. As with all other TDI starters, no lubrication is designed into ail TURBOTWINS. This low gear ratio allows
the turbine motor to spin at low speeds for long bearing life.
required in the air supply.
At a typical 3000 rpm pinion speed, the turbine is cruising at
You need to review the rest of this manual before installing a low 22500 rpm.
your TDI TURBOTWIN starter.
A simple and reliable inedia drive delivers the torque to the
pifian. The pinion is thrown out to engage the engine's ring
Note
gear by the turbine motor's acceleration. Lighter weight
Throughout this manual, the term "air• is used to denote the rotating parts used in the TURBOTWIN provide low inertia
starter drive rnedium. Unless atherwise stated, rneans
and even "softer" engagement. In the event of over-
either compressed air or natural gas.
pressure, the friction clutch used in every TURBOTWIN
protects ring gear teeth from static torque overtoads. In
addition, an inertia engaged starter eliminates the need for
WARNINGS, CAUTIONS AND NOTES complex pre-engagement control plumbing...and is easier
to install and maintain than pre-engaged type starters.
Certain types of information are highlighted in this manual
for your attention: 1.2 PRODUCT IDENTIFICATION
WARNING - used where injury to personnei or Figure 1 lists the available part numbers for the TD1
damage to the equipment is likely. TURBOTWIN Starters. The starter nameplate which is
pinned to the turbine housing contains the following
CAUTION - used where there is the possibility of information: model number, serial number, part number,
damage to the equipment. direction of rotation and the maximum rated operating
pressure. An example nameplate is shown in Figure 7.
NOTE - used to point out special interest
information. The model number is a shorthand description of the part
number. The part number is described as follows:
Publication T1-702
2 Issued 16June1995
TDI TURBOTWIN
FROM TECH DEVELOPMENT 1NC
-1 60001 1— DUO O MI 5t13007PCA777" O\

R - RIGHT MANID ROTATION
L - LEFT MANO ROTATION
Engine Ay Starters
DRIVE ASSEMBLY COOE FROM TECH DEVELOPMENT, INC
(SEE FIGURE 6)
A BARBER—COLMAN COMPANY
CHASSIS TYPE DESIGNATION 6800 POE AVE., DAYTON, OH 45414
B - SAE 3 MOUNT, MIGMER HORSEPOWER
(SEE FIGURE 2) NO. SERIAL NO.
- HEAW DUTY "O" SME MOUNTING
(SEE FIGURES 4 AND 5)
T 11 2 B 9 5 0 4 — 21 8
F - SAE 3 MOUNT, LOWER HORSEPOWER
(SEE FIGURE 3) PART NUMBER
ENGINEERING ASSEMBLY
DRAWING NUMBER
T 11 2 — 6 0 0 0 1 — B 1
NUMBER OF NOZZLES CV (RH) ccv (LH)
(6, 12 OR 21) AIR DR NAT, GAS
TURBOTWIN FAMILY OF X USAGE
STARTERS
PSIG
The direction of rotation is either right had or left hand
MAX PRESS. 150
rotation as defined by Figure 8. Right Hand rotation is MEASURED AT INLET VHILE OPERATING
PROOF PRESSURE OF HCIUSING IS 600 PSIG
defined as counterclockwise rotation as viewed from the
exhaust end of the starter. WARNING:111prGag10 rgagT 121:11T'liTHeur
The serial number is coded as follows: n ilt.
•
. nArrUT ISMACIOG tJ
Figure 7. Nameplate
95 04 — 218
SEQUENTIAL NUMBER
LEFT HAND RIGHT HAN

MONTH MANUFACTURED ROTATION ROTATION
\\\
YEAR MANUFACTURED
The maximum operating pressure is also stamped on the

nameplate. The example nameplate shows 150 psig. This
pressure is measured at the check port on the starter inlet
with the starter in operation.
CAUTION
Exceeding the maximum operating pressure shown on the Figure 8. Direction of Rotation as viewed
nameplate may result in drive failure, damage to the starter, from exhaust end of Starter.
damage to the engine or cause personal injury.
The proof pressure is 600 psig and is also shown on the

nameplate. This means the turbine housing will not burst 1.3 PHYSICAL CHARACTERISTICS
when subjected to a static pressure of 600 psig.
Figures 2, 3, 4 and 5 show the outlines and package
gures 2, 3, 4 and 5 show the installation drawings for the dimensions of the four sizes of TURBOTWIN starters.
tour basic variations of the TURBOTWIN Starter.
Publication T1-702 3
lssued 16 June 1995
TDI TURBOTWIN
PINION MAX STALLft TDI DRIVE
PART NUMBER PRESSURE PRESSURE
MODEL NUMBER ROTATION TORCUE lb- NUMBER
RANGE (PSIG) RANGE (BAR)
RIGHT HAND 300 1-18828
T121-60001-B1R 30 - 90 3.1 - 7.2
T121B
LEFT HAND 300 1-19083
T121-60001-B2L 30 - 90 3.1 -7.2
T1218
T112-60001-81R 60 - 150 5.2 - 11.4
T1128
LEFT HAND 300 1-19083
T1128 T112-60001-B2L 60 - 150 5.2 - 11.4
RIGHT HAND 160 - 2-22147
TI 06-60002-F3R 60 - 150 5.2 - 11.4
T106F
LEFT HAND 160 2-22148
TI 06-60002-F4L 50 - 150 5.2 - 11.4
T106F
T112-60002-F3R 30 - 90 3.1 - 7.2
T112F
LEFT HAND 160 2-22148
T112-60002-F4L 30 - 90 3.1 - 7.2
T112F
TI 21-60003-D1R 30 - 90 3.1 -7.2
T121D
LEFT HAND 300 1-19083
T121-60003-D2L 30 - 90 3.1 - 7.2
T121D
T112D T112-60003-D1R 60 - 150 5.2 - 11.4
LEFT HAND 300 1-19083
T11 2-60003-02L 60 - 150 5.2 - 11.4
T1120
T112-60004-D5R 60 - 150 5.2 - 11.4
T1120
5.2 - 11.4 LEFT NANO 300 2-22796
7112D T112-60004-06L 60 - 150
3.1 - 7.2 RIGHT HAND 300 2-22795
TI 21D T121-60004-05R 30 - 90
30 -90 3.1 7.2 LEFT HAND 300 2-22796
T1210 T1 21-6000-4-06L
_ _ .....
Figure 1. Starte
Figure 2 shows the Models T11213/T121B which are 20.1" pressures. Pinion speed is shown on the horizontal axis.
The pinion torque is shown along the left edge vertical axis.
long oyera!! and 8.2" in height. This model weighs 54
The shaft horsepower is shown along the right edge vertical
pounds. The turbine housing diameter is 6.8" which is
axis. Air consumption retes are given for the various drive
common to all TURBOTWINS. The rotary inedia of all
lb-in^2. pressure Unes. These performance curves feature air as
rotating components is
the drive gas and have open exhaust (standard exhaust
guard) which have basically no back pressure.
Figure 3 shows the Models T106F/T112F which are 17.4"
long overall and 8.2" in height. This model weighs 47
pounds. The turbine housing diameter is 6.8". The rotary 2.0 INSTALLING THE STARTER
inedia of all rotating components is lb-in^2.
WARNING
Figure 4 shows the Models T112DfT121D which are 20.1" Do not operate this starter unIess it is property attached to an
long overail and 8.4" in height. The mounting flange is 10.2" engine.
wide. This mode! weighs 70 pounds. The turbine housing
diameter is 6.8". The rotary inedia of all rotating
components is lb-in^2.
Information en typical TURBOTWIN installations is shown
Figure 5 shows the Models T106F/T112F which are 20.4" in Figures 13 and 14. The components illustrated may vary
long overall and 8.4" in height. The mounting flange is 10.2" in shape, but there must at least be an air source, a starter
wide. This model weighs 70 pounds. The turbine housing valve or switch and an air piloted relay valve in arder to
diameter is 6.8". The rotary inedia of all rotating property insta!! the TURBOTWIN starter. Refer te Section 3
components is lb-in^2. for information on TDI accessories.
1.4 PERFORMANCE 2.1 GENERAL
Graphs of the performance curves are shown in Figures 9 Figure 13 shows a typical starter installation using
through 12. These graphs feature pinion torque versus compressed air. The starter is mounted to the SAE 3 engine
pinion speed (rpm) at constant drive air pressures and shaft mounting pad and is secured with three 5/8" bolts on
horsepower versus pinion speed at constant drive air TURBOTWIN models T1XXB and T1XXF. Mode! T!XXD
Publication T1-702
Issued 16June1995
4
TDI TURBOTWIN
SAE 3 MOUNTING FLANGE

CLEARANCE HOLES FOR
5/8 DIA BOLTS
AIR INLET PORT
DRIVE PRESSURE CHECK PORT 2" NPT -MOUNTING SURFACE
1/4 NPT 14.76
5.750 DBC
3X 120
3.624/3.621
DIA PILOT
.81
2.?6
.40
GAS VENT PORT
(3/8 NPT) MUST BE 2.00 6.76 DIA TYP
PIPED AWAY WHEN 3.52 —
USING NATURAL GAS MOTOR MAY BE ROTATED TO (12)
DIFFERENT POSITIONS RELATIVE TO
9.95 TO DRIVE OPENING FOR BEST INLET PORT LOCATION
MOUNTING
SURFACE EXHAUST PORT - STANDARD WITH TURBINE EXHAUST
GUARD INSTALLED. OPTIONAL EXHAUST PORT FITTINGS
AVAILABLE. FOR EXAMPLE:
3" 90 DEGREE ELBOW KIT (T100-27015)
PARTIAL VIEW A -A
3" EXHAUST KIT (52-26947)
ECP EXHAUST KIT (T100-27068)
MUFFLER KIT , 21 NOZ (T100-27074)
MUFFLER KIT, 6/12 NOZ (T100-27075)
Figure 2. Model T112B/T121E3 TURBOTWIN
has the heavy-duty "D" style mounting flange which also All TURBOTWINS have the capability to rotate the inlet port
uses three 5/8" bolts. relative to the drive opening for the optimum inlet port
location. the number of different positions is 6 to 12
The air line to the starter contains a pressure regulator depending on mode! and application.
(when necessary) and a manual or remotely controlled
valve. AH TURBOTWIN starters features a 2" NPT pipe The starter should be installed with the inlet valve in a
thread on the inlet port. position between horizontal and straight down. Any
condensation will be restricted to the air Unes, and not in the
Most compressed air installations may use the standard starter.
exhaust guard. Figure 17 fists the optional exhaust hardware
kits. Figure 18 shows illustrations of the various exhaust CAUTION
options.
All screw threads are treated at the factory with a fastener
retention compound. Every screw and tapped hole must be
2.2 ORIENTATION OF THE STARTER clean and have a drop of Loctite 290 applied to the threads
before being reinstalled.
If the factory orientation of the starter's pinion housing
ssembly, in relation to the inlet port, does not fit your
igine installation, these components can easily be re-
oriented. Refer to Figures 2, 3, 4 and 5.
Publication T1-702
Issued 16 June 1995 5
TDI TURBOTWIN
SAE 3 MOUNTING FLANGE

CLEARANCE HOLES FOR
5/8 DIA BOLTS
DRIVE PRESSURE CHECK PORT AIR INLET PORT
1/4 NPT 2" NPT -MOUNTING SURFACE
12.67
8.17 4.50
.25
3X 120• 5.750 DBC
3.524/3.821
DIA PILOT
.8
2.06
.75
MESH
••• 8.78 DIA TYP
GAS VENT PORT
(3/8 NPT) MUST BE 3.51
PIPED AWAY WHEN
USING NATURAL GAS MOTOR MAY BE ROTATED TO (12)
DRIVE OPENING FOR BEST INLET PORT LOCATION
7.88 TO
MOUNTING
EXHAUST PORT - STANDARD WITH TURBINE EXHAUST
GUARO INSTALLED. OPTIONAL EXHAUST PORT FITTINGS
3' 90 DEGREE ELBOW KIT (T100-27015)
PARTIAL VIEW Á • A 4" EXHAUST KIT (52-26949)
Figure 3. Model T106F1T112F TURBOTWIN
2.2.1 MODELS T112B/T121B 2.2.2 MODELS 1106F/T112F
Refer to Figure 2. The drive housing may be rotated to 12 Refer to Figure 3. The drive housing may be rotated to 12
different positions relative to the inlet port. This task should different positions relative to the inlet port. This task should
be completed prior to installing the starter on the engine. be completed prior to installing the starter on the engine.
The following procedure describes how to accomplish this. The following procedure describes how to accomplish this.
First, remove the (6) 5/16" X 1.5" long bolts by loosening the First, remove the (6) 1/4" X .75" long screws which attach
(6) nuts. Next, rotate the drive housing without removing it the drive housing to the turbine housing. Next, rotate the
from the starter to the desired position. Clean the bolts and drive housing without removing it from the starter to the
nuts with Loctite Safety Solvent or equivalent. Reinstail the desired position. Clean the screws with Loctite Safety
;6) bolts and nuts using Loctite #290 Threadlocker adhesive Solvent or equivalent. Reinstail the (6) screws using Loctite
Dr equivalent. Torque the bolts and nuts to 25 lb-ft #290 Threadlocker adhesive or equivalent Torque the
maximum. screws to 10 lb-ft maximum.
Publication T1-702
3 lssued 16.June1995
TDI TURBOTWIN
CLEARANCE HOLES FOR 5/8 DIA BOLTS

AIR INLET PORT
r NPT
DRIVE PRESSURE CHECK PORT -MOUNTING SURFACE
1/4 NPT 9.40
4.91 10.39
R 3.38
.69
1.25
5.999 DIA 9.000 OBC
5.995
(4.13 DIA)
25
..
XHAUST
"■~74 itiCej7
8.10 DIA ryP

5.12
6.24 .88
- GAS VENT PORT MESH
(3/8 NPT) MUST BE 7.40
PIPED AWAY WHEN
8.88
USING NATURAL GAS
MOTOR MAY BE ROTATED TO (12)
4.60 TO DRIVE OPENING FOR BEST INLET PORT LOCATION
MOU NTING
SURFACE EXHAUST PORT - STANDARD WITH TURBINE EXHAUST
GUARD INSTALLED. OPTIONAL EXHAUST PORT FITTINGS
90 DEGREE ELBOW KIT (T100-27015)
PARTIAL VIEW A-A 3" EXHAUST KIT (52-28947)
EXHAUST KIT (52-26949)
MUFFLER KIT, 6112 NOZ (T100-27075)
Figure 4. T112D/T121D (Standard Mesh) TURBOTWIN
2.2.3 MODELS 2D/T121D 2.3 INERTIA DRIVE ASSEMBLY
Refer to Figure 4 or 5. The drive housing may be rotated to The inedia drive assembly consists of a friction clutch pack
12 different positions relative to the inlet port. This task and the drive pinion which rides on a helical shaft. The
should be completed prior to installing the starter on the pinion is thrown out to engage the engine's ring gear by the
engine. The following procedure describes how to turbine motor's acceleration. Lighter weight rotating parts
accomplish this. First, remove the (6) 5/16" X 1.25" long used in the TURBOTWIN provide low inedia and even
screws which attach the drive housing to the turbine "softer" engagement. In the event of over-pressure, the
housing. Next, rotate the drive housing without removing it friction clutch used in every TURBOTWIN protects ring gear
from the starter to the desired position. Clean the screws teeth from static torque overloads.
with Loctite Safety Solvent or equivalent. Reinstall the (6)
screws using Loctite #290 Threadlocker adhesive or The torque carrying limit on the friction clutch pack is factory
quivalent. Torque the screws to 25 lb-ft maximum. set by the manufacturer. Modeis T112B/T121B and
T112D/T121D are set to 275-300 lb-ft. Modeis
issued 16 June 1995
TDI TURBOTWIN
CLEARANCE ROLES FOR 5/8 DIA BOLTS

AIR INLET PORT
2' NPT
DRIVE PRESSURE CHECK PORT MOUNTING SURFACE
114 NPT 9.40
10.78
R 3.38 7
5.999 DIA
1.25
5.995
9.000 OBC
-LE=11 1
1111111
11 11"
GAS VENT PORT

(318 NPT) MUST BE
PIPED AWAY WHEN
USING NATURAL GAS
Wall es.131
7.40
9.25
MOTOR MAY BE ROTATED TO (38)
1.25
MESH 5.12 TYP.

DRIVE OPENING FOR BEST INLET PORT LOCATION
4.80 TO
MOUNTING EXHAUST PORT - STANDARD WITH TUR8INE EXHAUST
SURFACE GUARD INSTALLED. OPTIONAL. EXHAUST PORT FITTINGS
3" 90 DEGREE ELBOW KIT (T100-27015)
EXHAUST KIT (52-28947)
PARTIAL VIEW A - A EXHAUST KIT (52-28949)
Figure 5. Model T112D/T121D (Long Mesh) TURBOTWIN
PINION PRESSURE CLUTCH LENGTH TRAVEL PIN

BENDIX TDI PART ROTATION PITCH #TEETH/
BLANK PITCH DIA ANGLE SET. O.D.
CODE NUMBER
2.000 20 275-300 8.875 1.062 2.250
1 1-18828 R.H. 6/8 12/12
2.000 20 275-300 8.875 1.062 2.250
2 1-19083 L.H. 6/8 12/12.
2.000 20 140-160 7.450 1.000 2.250
3 2-22147 R.H. 6/8 12/11
2.000 20 140-160 7.450 1.000 2.250
4 2-22148 L.H. 6i8 12/11
12/12 2.000 20 275-300 9.312 1.4375 2.250
5 2-22795 R.H. 6/8
12/12 2.000 20 276-300 9.312 1.4375 2.250
6 2-20927-001 L.H. 6/8
. _ . .
igure 6. lnertia Unve
Publication T1-702
Issued 16Junel 995
8
TDI TURBOTWIN
Libe grease the starter's drive teeth with chassis lube

106FIT112F are set to 140-160 lb-ft.
and 1 mount the TURBOTVV1N starter on the engine.
Tig; all mounting hardware as appropriate. Make sure
All TURBOTW1N starters listed in this manual have a pinion
to se Loctite Threadlocker #290 or equivalent on the
with 6/8 diametral pitch teeth.
starter mounting bolts. Torque the three 5/8" screws to 100
The pinion gear data and clutch torque settings are listed in lb-ft.
Figure 6.
After mounting the starter to the engine, attach the supply
Back lash is the "free play" between the mesh of two gears. air line to the starter, connect the control air lines and install
Figure 15 shows the backlash between two gears. the solenoid between the igrillion switch and air piloted relay
Maintaining the proper gear backlash setting allows the valve. See Sections 2.4, 2.5 and 2.6. The following sections
gears to mesh smoothly. Proper backlash and alignment describe the connection of the supply line, exhaust piping
allow smooth engagement/disengagement of the pinion and optional control Unes.
gear and loads the tooth face surfaces evenly producing
longer gear life. The correct backlash setting for 6/8
diametral pitch gearing used on larger engines is as follows: 2.4 Supply Line Installation
Minimum backlash .015 inch CAUTION

Maximum backlash .025 inch Be sure to either bleed the pressurized air reservoir and /or
safety the air system such as closing all valves prior to Installing
To check the backlash, the pinion will need to be rolled out any starter supply line.
onto the end of the drive prior to starter installation. This can
be accomplished by using a hex drive wrench to rotate the
turbine end of the starter while holding the pinion from All TURBO TW1N starters come standard with a 2" NPT
rotating. The pinion will simply waik to the end of the shaft. female pipe thread for the inlet connection port. Figures 13
An access hole to reach the turbine screw is provided in the and 14 show typical starter installations. The supply line
urbine standard exhaust guard. The starter must then be consists of the line from the air source, a pressure regulator
istalled on the engine. Checking backlash can be (when necessary), a manual or relay valve, and then the
accomplished using a dial indicator or a simple blade-type connection to the starter inlet. Hard piping may be used, but
feeler gauge. Because ring gears are not usually perfectly a section of flexible tubing should be used right at starter for
round, it is necessary to check backlash at several (six or mobile applications to prevent leaks due to engine vibraban.
more) points around the circumference of the ring gear.
Average the highs and lows to allow a setting that is in the A turbine driven starter does not require lubrication in the
supply air. Therefore, if a vane-type starter motor is being
range cited aboye.
replaced, TDI recommends that all lubrication devices and
lines be removed to minimize flow restrictions.
G eat
WARNING
If a fuel (pulse) lubricator has previously been installed in the
system, disconnect and plug the line to eliminate spraying diesel
fuel on the engine.
Care must be taken to ensure that all inlet supply line piping
is no less than 1.5" (38 mM) and that all valves used are
capable of passing the required air flow.
Pinion
NOTE
Vaives with a O, of 40, or higher, are recommencled.
Figure 15. Inedia Drive Pinion Backlash
Setting the correct backlash may involve "shimming" and/or

noving the starter bracket(s). An adjustable starter bracket If the supply line must be longer than 20 feet (6.1M), then
lesign will simplify this procedure. Always re-check the inlet supply line piping should be increased to 2" (50
backlash after the installation of a ring gear replacement. mM) to assure proper performance by your TURBOTW1N.
lssued 16 June 1995
TDI TURBOTWIN
325
I I 90 psig @ 1560 scfm 90
300 •Madmuni- T6rque-
60 psig @ 1070 scfm
275 i TrartsmittaLlayJD.rive
30 psig @ 620 scfm 75
250 -5°-19---
225
200
175
45
150
125 30 psi,
30
100 -
75
15
50
25
10 15 20 25 30 35 40 45 50 55
Pinion Speed (rpm) / 100
Figure 9. Performance Curves for Model T12113/1-121D

(21 Nozzles, Air, 7.5:1)
325
I MaxiMuml4Orque 150 psig @ 1360 scfm
300 90
171--ansmittea-by nve 120 psig © 1090 scfm
275 90 psig @ 860 scfm
250
—1 1 60 psig © 610 scfm 75
225
200 60
o
1
175
150 60 psig 45
-o
125
100 30
75
50 15
25
o
0 5 10 15 20. 25 30 35 40 45 50 55
Pinion Speed (rpm) /100
Figure 10. Performance Curves for Model T112S/T112D

(12 Nozzies, Air, 7.5:1)
Publication T1-702
10 Issued 16June1995
TDI TURBOTWIN
I/Q
90 pSig Maximum lorqu 90 psig @ 860 scfm
Trantmitted by D'Ove 60 psig @ 610 scfm
150 45
30 psig @ 370 scfm
O psig
125
100 30 o
_o
75
ig -o
50 15
25
0
5 10 15 20; 25 30 35 40 45 50 55
Pifian Speed (rpm) / 100
Figure 11. Performance Curves for Model T112F

175
150 psig ; Maxirrum Torquei 150 psig @ 680 scfm
Tranmitte1 by Drive 120 psig @ 550 scfm
150 90 psig @ 430 scfm 45
120 psig 60 psig @ 310 scfrn
125
30
60 psrg
50 15
25
0
5 10 15 20; 25 30 35 40 45 50 55
Pinion Speed (rpm) / 100
Figure 12. Performance Curves for Mode! T106F

Publication T1-702
TDI TURBOTWIN
STARTER INSTALLATION - AIR USAGE

O OPTIONAL AIR
PRESSURE GUAGE
1-
1 > I MANUAL STARTER
11 1,9 / CONTROL VALVE
-5;
14 HOSE OR
114* PIPE SINGLE
C) OPTIONAL PRESSURE
REGULATOR e STARTER
APP
FROM AIR I I IN
SOURCE O
—=.
AIR-PILOTEO
RELAY VALVE
FFt •
STARTER
CONTROL
VALVE
FROM AIR
SOURCE
DUAL
STARTER
NOTES:
IF DUAL STARTERS ARE USED, A SINGLE PRESSURE REGULATOR DEVICE Sh4OULD BE USED IF PRESSURE
C.)
REGULAT1ON 15 REQUIRED.
REFER TO SECTION 4.0 FOR HAROVVARE ANO ACCESSORIES AVAILABLE FROM TOL
O
NPT IDCHAUST FLANGE ALL STARTERS, 15 NOZZLES ANO HIGHER.
NPT EXHAUST FUNGE- ALL STARTERS, 14 NOZZLES ANO HIGHER.
INLET PIDE SIZE 1.5•-ALL STARTERS, 14 NOZZLES ANO LOWER

O
2.0*- ALL STARTERS, 15 NOZZLES ANO LOWER
TO 1' NPT REDUCING BUSHING- ALL STARTERS, 14 NOZZLES AND LOWER.

O
Figure 13. Typical Starter Installation - Compressed Air
Publication T1-702
12 Issued 15June1995
TDI TURBOTW1N
STARTER INSTALLATION - NATURAL GAS USAGE

TO START O OPTIONAL
CONTROL NATURAL GAS PILOTEO
RELAY VALVE
1/4" HOSE OR PIPE
FLEX COUPLING
(RECOMENDED FOR PIPE)
11/2 MIN
HOSE OR PIPE
AIR/GAS {)
SUPPLY
0 OPTIONAL HAND OPERATED GAT

PRESSURE REGULATOR OR BALL VALVE
STARTER PRESSURC
111'11.111
CHECK PORT-1/4" NPT
\:(
PIPE SUPPORT
/
NATURAL GAS
EXHAUST
•»"C11..—
PIPE DIAIVIETER TO
MATCH STARTER TURBINE HOUSING VENT
EXHAUST FLANGE
PORT (OPPOSITE SIDE)
(GAS USE) MUST BE PIPED AWAY-3/8" NPT
(GAS USE)
NOTES:
O IF DUAL STARTERS ARE USED, A SINGLE PRESSURE REGULATOR DEVICE SHOULD BE USED IF PRESSURE
REGULATION 15 REOUIRED,
O REFER TO SECTION 4.0 FOR HARDWARE ANO ACCESSORIES AVAILABLE FROM TE/
O NPT EXHAUST FLANGE ALL STARTERS, 15 NOZZLES ANO HIGHER.

NPT EXHAUST FLANGE ALL STARTERS, 14 NOZZLES ANO HIGHER.
• INLET PIPE StZE: 1.5" ALL STARTERS, 14 NOZZLES ANO LOWER

2.0* ALL STARTERS, 15 NOZZLES AND LOWER
O 2 TO NPT REDUCING BUSHING - ALL STARTERS, 14 NOZZLES AND LOWER.
Figure 14. Typical Starter Installation - Natural Gas
Publication T1-702
TDI TURBOTWIN
11F-25025-28 SCREW
EXHAUST END
OF STARTER
AVAILABLE 50 SERIES
DI EXHAUST ADAPTOR
2-26766 EXHAUST SPACER 9-90001-050 "0" RING

9-93556-004 PLUG
Figure 16. Part Number 52-26839 Exhaust Adaptor Kit
Because turbine starters such as the TURBOTWIN are located very close or even on the starter inlet for better
sensitive to flow restrictions, care must be taken to use performance. Pneumatic or electrice] control unes may be
uniform hose or tubing and fittings for connection of the routed virtually anywhere for the customer's preferred
supply air line. Tees, elbows and line length must be kept operating station. This type of vaive actuates from a fully
to a minimum. TDI recommends that hose or flex couplings closed to a fully open position very rapidly (usually Y2
be installed to eliminate possible leakage caused by strain second or less). TDI offers a variety of relay valves such as
3n the supply air line. P/N RLVA-25683-001-2-01 which is a 1-1/2" port,
pneumatically actuated valve.
Vormally, an air strainer is not required. In dirty
3nvironments, use of a #40 mesh Y-strainer Es The supply Eine should be dry-fitted for proper
ecommended. The TURBOTWIN is highly tolerant of dirt alignment/locaton prior to final assembly. All pipe threaded
n the air line, however, the starter !Efe can be increased with joints should be sealed with Loctite Pipe Thread Sealant
he use of the air strainer. (TDI P/N 9-94085) or equivalent for leak tight joirits prior to
final assembly. Be sure to tighten all joints to proper torque
rhe pressure regulator is required when the air supply after final assembly.
)ressure is great enough to exceed the starter operating
)ressure (at the inlet port) and/or the maximum torque. CAUTION
In ccld climate conditions, care should be taken whiledesigning
\ manual ball vaive may be used to admit air to the starter. your installation to prevent condensation from developing in the
'he manual valve should be located in a safe position away starter system. In systems with a regulator valve or relay vaive,
rom the engine. there is the possibility of freeze-up.
\ preferred vaive is pilot-operated relay valve which can be

;neumatically or electrically actuated. The vaive can be A tee connection with a quick disconnect can be added to
Pubkabon T1-702
4 Issued 18Junet 995
TDI TURBOTWIN
inlet This will allow an externa' air source to be used to TDI. Also see Section 3. All starters using natural gas
—complish a ''biow start" if the system freezes. Once the must be piped away according to industry codes and
engine has been started, the other system components may local regulations.
be thawed.
The performance of a turbine starter will be decreased
This instaliation option may be especially useful in off- because of back pressure when smaller than
highway equipment. recommended exhaust piping is installed. When the
starters exhaust is to be piped away, refer to Figure 8 for
CAUTION minimum piping size and TDI kit numbers. If back pressure
hampers starter performance, compensation can be made
Especially on new installations, it is strongly recommended to blow by increasing the supply pressure. Consult your TDI
out the suppty line with air to remove possible dirt and weld slag prior distributor for advice.
to final connectíon to the TURBOTWIN starter. Be sure to secure the
free end of the supply line prior to the blow-clown.
The various exhaust fitting options are Usted and shown in
Figures 17 and 18, respectively. The standard exhaust
KIT PART DESCRIPTION USED ON treatment is the turbine exhaust guard P/N 52-420. This
NUMBER MODELS exhaust guard should not be used with natural gas.
52-420 Exhaust Guard Screen Kit All
In installations with a starter length restriction, the 3" right
T100-27068 Exhaust Closure Plate Kit All angle exhaust elbow may be required. The 3" NPT 90
T100-27015 3 Inch NPT 90 Degree Elbow All degree elbow kit is PM T100-27015 and features a welded
Kit steel pipe with a mate 3" NPT pipe thread. An aluminum
52-26947 3 Inch NPT Straight Fitting All adapter ring is included with this kit to attach this elbow
Kit fitting to the TURBOTW1N.
52-26949 4 Inch NPT Straight Fitting All
Kit The exhaust closure plate kit is P/N T100-27068. This kit
TI 00-27075 Short Muffler Kit T106F/T112F features a movable plate which protects the inside of the
T121B/T121D starter from dirt when the starter is not operating. The end
plate opens during starter operation. This exhaust fitting
T100-27074 Long Muffler Kit T121 B/T1210
should not be used with natural gas.
52-26839 Exhaust Adaptor Kit All
Figure 17. Exhaust Hardware Kits The 3" NPT straight exhaust fitting features a female 3"
NPT pipe thread. This kit is P/N 52-26947. An adapter ring
2.5 Inlet Pressure Port is included with this kit.
A 1/4" NPT port is located on the exhaust side of the air The 4" NPT straight exhaust fitting features a female 4"
inlet. This port may be used to check the supply pressure at NPT pipe thread. This kit is P/N 52-26949. An adapter ring
the starter when the starter is operating. Remove the 1/4" is included with this kit.
NPT pipe plug and save for later use. Instan a 1/4"
mínimum size tubing to the port. Route the tubing away The muffler kit for the 6 or 12 nozzle TURBOTW1N starter
from the starter to a safe location away from the engine. is PM T100-27075. This exhaust fitting should not be used
Instali a pressure gauge on the tubing. This pressure with natural gas.
monitoring line/gauge may be permanently installed. Use
Loctite Pipe Thread Sealant or equivalent. Alternately, a The muffler kit for the 21 nozzle TURBOTWIN starter is P/N
pressure transducer may be installed at the pressure check T100-27074. This exhaust fitting should not be used with
port and electrical lines would be routed to a digital display natural gas.
at the operator's station.
All older TDI Series 52 exhaust options may be used on the
This pressure port is invaluable in diagnosing air starter TURBOTW1N with the exhaust adapter kit P/N 52-26839. A
performance problems. typical installation using the adapter ring is shown in Figure
16. This adapter ring must be used with the older
2.6 Exhaust Piping fittings, otherwise the starter will be damaged.
turbine exhaust may be plumbed away from the starter Exhaust piping should be routed downward to help prevent
—ea. 3" NPT and 4" NPT exhaust fittings are available from any accumulation of condensate in the starter motor.
Publication T1-702
TDI TURBOTWIN
3.13
4.54 CLOSEO—«1
ir
ir
3.17
EXHAUST GUARO OPEN
ADAPTER RING
STANDARD ON ALL MODELS
EXHAUST CLOSURE PLATE
KIT 52-420
KIT T100-27088
5.21
r 2.70
3" NPT 90' ELBOW FITTING
KIT T100-27015
oil r
ADAPTEN RING ADAPTER PINO
3" NPT STRAIGHT FITTING NPT STRAIGHT FITTING

KIT 52-28947 KIT 52-28949
3.70
ooaa000.000, lea
OOPOOC•00~00CKX
>00=004
r"....000000.00.
=
croo...00000~
•a :c
ozz
e zo= e
000.00.0.26.000«
0000 000.00000~
x°00°°.5
.0.°m «
000.0000..000
MUFFLER
KIT T100-27075
16.52
1
05000,, 0 0000.??. ....0000000
0000000.0000000000000000.00000000000
0000000raeoa.c.0.0
0.,1% ocoo-.000%00000
000000 ..:~0*OUÓ
a
«Hm %Oe 00,10.0,0"0 .
n, O /00"0. 0 O O 0 O O O 0:.C• O O O 000
ie.000000000.0000.2000000000.2. 3.000000000
1
a=1.1115r10==Woár ooto
''' 00,1% 00
000000.000000' 00.}»300000000000~.00-00
00.0000acocw000d=0000.00000000C0000000
‹,,0"04.5 ,,O 00.0Z0,000000000(20~00C00000
,n0<1,
MUFFLER
KIT T100-27074
Figure 18. Illustrated Exhaust Hardware Options
Publication T1-702
16 !asilad 16June1995
TDI TURBOTWIN
the overhung section of the starter is not otherwise DESCRIPT1ON PART NUMBER
,upported, TDI recommends that the exhaust piping be Solenoid Control Air Vatve, 24VDC, 1.5" RLVA-25553-014-1-01
supported with a suitable bracket(s). Buna-N
Solenoid Control Air Vatve, 24VDC, 1.5", RLVA-25681024-2-01
2.7 Natural Gas Installation Viton
Solenoid Control Air Valve, 110VDC, 1.5" RLVA-25663-110-2-01
The installation of the starter using natural gas is similar to
the air installation except all fittings, piping, valves and Solenoid Control Air Valve, 120 VAC, 1.5" RLVA-25683-120-2-01
regulators must be capatible with natural gas. Valve, Natural Gas, Manually Operated / 52-93508
Spring Loaded, 1.5"
Proper control of natural gas is a major consideration when Valve, Natural Gas, Manually Operated / 52-9350B-400
used in the starter system. All starters using natural gas Spring Loaded, 2.0"
must be piped away on the exhaust according to Pressure Regulator, Natural Gas, T, 300 52-93552
industry codes and local regulations. PSIG Max Upstream Pressure
Pressure Regulator, Natural Gas, T, 125 52-93553
There is a natural gas vent port in the turbine housing that PSIG Max Upstream Pressure
is plugged for compressed air use. This vent is used to
Y-Strainer, 1.5 NPT, Natural Gas, 600 52-93549-100
remove any natural gas which could leak past the primary
PSIG
turbine shaft seal. Remove this 3/8"NPT plug and install a
line to carry gas away from the starter area and vent to Y-Strainer, 2.0" NPT, Natural Gas, 600 52-93549-200
PSIG
atmosphere; refer to Figures 2,3,4 and 5. Do not connect
this vent line to the starter exhaust line. Y-Strainer, 1.5" NPT, Air, 250 PSIG 52-93550-100
Y-Strainer, 2.0" NPT, Air, 250 PSIG 52-9355-200
CAUT1ON 9-94121
Grease, 1 Lb Can
Do not connect the turbine housing vent line to the turbine exhaust Grease, 16 Oz Tube 9-94121-002
line: exhaust gas can pressurize the turbine housing.
Anti-Seize Compound, 1 Oz Tube 42-94061
Anti-Seize Compound, 1 Lb Can 9-94061
3.0 HARDWARE and ACCESSORIES
Sealant, Pipe Thread, Loctite 59231, 1.69 9-94035
Oz Tube
Refer to Figures 16 through 19 for exhaust hardware and
installation accessories available from Tech Development. Figure 19. (Continued) Installation Accessories
DESCRIPTION PART NUMBER 4.0 STARTER OPERATION
Pressure Regulator, Air, 1.5" 52-20724-100

Prior to operation, check that all connections are tight and
Pressure Regulator, Air, 2.0" 52-20724-200 free from leaks. Check the 1/4" NPT pipe pkkg (from
Pressure Gauge, O - 200 PSIG 52-21982 Section 2.5) or a pressure gauge/transducer and air line is
connected to the pressure port on the starter bid.
Pressure Gauge, with U-Clamp, 0 - 200 52-21982-100
PSIG
WARNING
Manual Control Valve, Air 52-93504
Do not operate the TDI TURBOTWIN starter with air pressen greater
Natural Gas Piloted Relay Valve, 1.5" 52-93505
that the pressure rating on the nameplate. This pressureísto be
Natural Gas Piloted Relay Valve, 2.0" 52-93505-100 measured at the starter inlet while the starter is running.
Air Piloted Relay Valve, Buna-N, 1.5" RLVA-25683-001-1-01
Air Piloted Relay Valve, Viton, 1.5" RLVA-25683-001-2-01 The maximum operating pressure limit is the inlet pressure
Air Piloted Relay Valve, High Pressure, RLVA-25683-001-3-01 when measured at the starter inlet pressure check port and
1.5" reflects all supply air pipe and valving losses. In order to
RLVA-25683-012-1-01
check the starter, a 1/4"NPT pipe tap connection is provided
Solenoid Control Air Valve, 12VDC, 1.5"
Buna-N in the inlet housing to attach a pressure gaugeltransducer;
refer to Figures 4 and 5.) IN NO CASE SHOULD INLET
Solenoid Control Air Valve, 12VDC, 1.5" RLVA-25683-012-2-01
Viton
OPERATING PRESSURE EXCEED 200 PSIG (14.8 BAR)
WITH AN OPEN EXHAUSTI This Will exceed the maximum
Figure 19. Installation Accessories
torque limit of the inedia drive assembly. The maximum
Publication T1-702
TDI TURBOTWIN
operating pressure limit of all modeis of TURBOTWIN WARNING

starters is shown in Figure 1. These maximum pressures Do not engage the starter while the engine is running.
assumes air as the working gas and an open exhaust (the
standard turbine exhaust guard). The standard exhaust
guard basically causes no back pressure.
The drive air pressure is the primary starter control
parameter. It is important, especially on new installations, to
The static supply pressure will always be higher than the
measure this pressure during several engine starts. The
operating pressure. As a guideline, the maximum pressure
secondary parameter is the starter pinion speed. This speed
limit (proof pressure) that the TURBOTWIN starter housings
is usually measured by knowledge of the engine starting
may be subjected to is 600 PS1G (42 BAR). System
speed and the starter cranking ratio. The cranking ratio is
pressure that exceeds the maximum operating limit must
the number of ring gear teeth divided by the number of
use a pressure reducer device to ensure that the operating
pifien teeth. The starter pinion speed is then found by
pressure limit to the TURBOTWIN starter is maintained.
multiplying the engine speed by the cranking ratio. The
pinion speed is usually 2000-3500 rpm for a typical engine
System pressure that exceeds the 600 PSIG (42 BAR) limit
must, in addition to pressure reducer devices, incorporate starting speed.
a pressure relief valve, set below 600 PSIG (42 BAR), in the
If the engine fails to fundan properly when first operated, or
supply air line.
its performance deteriorates with use, refer to the
Operator's Trouble Shooting Guide, Section 7.0. If you
All appropriate local pressure codes and pressure
cannot salve the problem, or repair is necessary, contact
limitations on other system components must be adhered
to and would supersede the guidelines given in this manual. your local TDI TURBOTWIN distributor or dealer.
Consult your TDI distributor if you have exhaust plumbing 4.2 Manual Valve Operation
which creates back pressure and reduces starter
The operator opens a valve manually to admit pressurized
performance. You may be able to increase the supply
air to the starter. As the engine approaches starting engine
pressure to restare the lost power.
speed, the operator must monitor the various engine
Follow the engine manufacturer's instructions for starting parameters or listen for the engine firing. Upon engine firing,
the operator must stop the air flow te Me starter by closing
the engine.
the manual valve.
4.1 Sasic Operation
Leaving.the air on te the starter more than ene second after
the engine is running, may result in damage to the starter.
The basic operation of the starter follows:
Pressurized air or natural gas is admitted to the starter by 4.3 Automated Start Panel
the opening of the manual or relay valve. The air expands
through the turbine which produces shaft rotation and As mentioned previously, the starter drive pressure will need
torque. The acceleration of the drive assembly causes the to be set. This pressure is measured at the starter inlet.
pinion to advance and engage the ring gear of the engine.
The starter motor torque causes the engine to accelerate. The speed control parameter will then need to be set.
The fuel and ignition systems now fire the engine. The Engine starting speed along with the cranking ratio number
starter is stopped by closing the manual or relay valve. can be used to determine starter pinion speed. The pinion
speed is usually 2000-3500 rpm for a typical engine starting
speed. Once the start sequence has begun, the air is
The TURBOTWIN features a unique two stage turbine
which limits the maximum starter speed from its admitted to the starter. The starter begins to accelerate the
aerodynamic design. The operator may prematurely engine. Once the firing speed of the engine is reached, the
decrease starter life by the continua! operation of the starter automated start panel may start fuel to the engine (diesel).
atter the engine has started. Upon a successful engine The engine will begin to accelerate under its own power.
start, shut the air off to the starter immediately. Minimizing The starter should be dropped out of the sequence at an
the time the starter is operating unloaded (i.e. the engine is rpm slightly higher than the firing speed, but certainly less
running) will maximize the starter life. lf a start is aborted, a than the engine idle speed.
restart may be attempted after the engine and the starter
The automated start panel should be set to monitor engine
have come to rest.
Pubtication 11-702
Issued 16Junel 995
18
TDI TURBOTWIN
speed and/or starter speed to determine air or and air off. Section 2.2 discusses the pardal disassembly in detall to
Do not use simply time as a control parameter. Avoiding change the orientaban of the air inlet relative to the starter
excessive over speed of the starter after the engine is firing mounting flange.
will maximize the starter !Ie.
Repair technicians or service organizations without turbine
5.0 PREVENTIVE MAINTENANCE starter experience should not attempt to repair this machine
until they receive factory approved training from TDI or its
The TDI TURBOTWIN starters provide distinct advantages representativas. If repair is required, consult your local TDI .
of size and efficiency as compared to electric motor, vane- TURBOTWIN dealer or distributor.
type or other turbine-type starters. It is important to properly
instan the starter to receive full benefit of these advantages. For safe and reliable operation of your TDI TURBOTWIN
Repair technicians or service organizations without turbine starter, use only genuine TDI replacement parts. The
starter experience should not attempt to repair this machine component part numbers are found in the Illustrated Parts
until they receive factory approved training from. TDI, or its Breakdown which is P/N T1-703. All models are covered in
representatives. this publication.
Proper operation and repair of your TD! TURBOTWIN

starter will assure continued reliable and superior
performance for many years.
5.1 Every Six (6) Months
Perform the following procedures at six(6) months intervais

if the normal cranking cycle is O - 10 seconds.
5.1.1 Check the amount and condition of grease in the

planetary gearbox. If gearbox requires re-greasing, only use
TDI grease. Approximately one (1) pint of grease is needed
to repack the gearbox.
5.1.2 Check the turbine bearing and carrier output bearings

for freedom of rotation without excessive play between
reces. lf bearings are damaged, replace them with genuine
TDI parts. Refer to TDI Service Manual for part numbers.
5.1.3 Place a small amount of chassis lube on the starters

pinion teeth.
5.2 Every Three (3) Months
Follow the six (6) month procedures if there is severe starter

loading or extended duraban crank cycles. Also perform
these procedures every three (3) months when starter is
usad for motoring the engine for maintenance or valve
adjustments.
Motoring Crank Cycle: 10 -60 seconds
Extended Crank Cycle: 60 seconds or longer
6.0 STARTER D1SASSEMBLY AND REPAIR
The TDI service manual P/N T1-701 provides a step by step

procedure to assemble and disassemble the TURBOTWIN
starter. All models are covered by this manual.
Publication T1-702
19
Issued 16 June 1995
TDI TURBOTWIN
TROUBLE PROBABLE CAUSE SOLUTION
1. Starter does not run; small A. Relay valve not fully opera. A. Repair or replace relay valve.
air flow from exhaust. B. Remove blockage or obstruction from nozzles.
B. Nozzle blockage.
2. Starter does not run; A. Broken turbine rotor. A. Replace all damaged parts.
normal air flow from exhaust. B. Repair or replace geartrain.
B. Broken gear train.
C. Damaged starter drive. C. Repair or replace starter drive.
3. Reduced Starter output A. Inlet air pressure too low. A. Increase air pressure in 10 PSIG (0.6 BAR) increments; DO NOT
power. EXCEED OPERATING LIMIT.
B. Inlet supply piping too small. B. Suppty piping must be a minimum oí 1.5" diameter.
C. Pressure regulator orífice too small. C. Increase orífice size or replace pressure regulator
D. Inlet supply line valve (ball, gate, relay, D. Insta!' larger valve.
piug) too small.
E. in line lubricator installed in supply line. E. Remove lubricator.
F. Y-Strainer in suppty line clogged. F. Clean strainer.
G. Excessive back pressure; exhaust G. Clean exhaust piping or increase size to at least the minimum diameter
restricted. recorrmended. '
H. Damaged turbine nozzle. H. Replace turbine nozzle.
I. Broken started drive. I. Repair or replace starter drive.
J. Wrong rotation starter. J. Replace with starter or proper rotation.
K Wrong size starter. K. Check the Application Guide for the correct starter.
4. Engine cranks too quickly. A. 'niel air pressure too high. A. Decrease air pressure in 10 PSIG (0.6 BAR) increments.
OR
If there is a manual shut-off valve in the supply line, partially close it.
OR
Instan a restriction orifice in the inlet supply line.
B. Wrong size starter. B. Check the Application Guide for the correct starter.
7.0 OPERATOR'S TROUBLE SHOOTING GUIDE
If repair is required, consult your local TDI TURBOTWIN

dealer or distributor.
For your nearest TDI dealer contact:
Phone: (513)898-9600 Customer Service

Fax: (513)898-8431 Tech Development Inc
6800 Poe Avenue
Dayton, Ohio 45414
Publication T1-702
20 Issued 16.Junel 995
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1111110 TRAS1111)14Ill. OIMe1411016.

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.
TDI TURBOTWIN
WARRANTY
TDI TURBOSTART ENGINE STARTER WARRANTY
Tech Development Inc. Warrants to the original user of the TDI TURBOTWIN starters that the starters and related
components manufactured by TDI will be free from defects in material and workmanship for a period of One (1) Year from
the date of purchase by such user. The conditions of this warranty ae: a) TDI is notified within this penad by retum of such
product to TDI or its authorized distributor or dealer, transportation prepaid by user; b) such product has been installed
according to TDI's specifications; c) product has not been misused, abused, or improperly maintained by user; d) the
defect is not the result of normal ,vear and tear; and e) such starter product has not been repaired with parís not
manufactured or authorized by TDI and that TDI installation and repair procedures as outlined in the appropriate manual
were properly followed.
Tech Development Inc. shall, at its option, either repair or replace, without charge, any such starter product found upon
TDI's examination to be so detective, or by mutual agreement, refund the user's purchase price in exchange for such starter
product. Repairs or replacements under this warranty are warranted for the remainder of the original warranty period.
Tech Development Inc. Makes no other warranty, and IMPLIED WARRANTIES INCLUDING ANY WARRANTY OR
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.
This warranty conbtitutes the entre obligation of Tech Development Inc. Relating to the sale and use of such product, and
TDI's maximum liability is limited to the purchase price of such product at the date of purchase. In no event whall TDI be
Hable for incidental, indirect, consequential or special damages of any nature from the sale of such engine starter product.
Issued 16 June 1995
TECH DEVELOPMENT INC.
6800 POE AVENUE • BOX 13557 • DAYTON OHIO • 45413-0557
PHONE: (937) 898-9600 • FAX: (937) 898-8431
Publication T1-702 16 June 95 AN95-414

End suction frame mounted pumps
Models F610AM, F810AM, F820AM, F1025AM, F1-610AM, F1-810AM,
F1-820AM, F1-1025AM and f0-510M Used on AJAX Compressors
Instructions such part is, upon request, returned to Seller's factory from
• Operation which it was shipped, transportation prepaid. This warranty
does not cover parts damaged by decomposition from
• Maintenance chemical action or wear caused by abrasive materials, nor

does it cover damage resulting from misuse, accident,
neglect, or from improper operation, maintenance,
Read this entire book modification or adjustment, This warranty does not
cover parts repaired outside Seller's factory without prior
before attempting to install, operate or repair this pump. written approval. Seller makes no warranty as to starting
Failure to read and comply with installation, maintenance equipment, electrical apparatus or other material not of its
and operating instructions will void the responsibility of the manufacture, since the same are usually covered by warran-
manufacturar and may also result in bodily injury as well ties of the respective manufacturers thereof.
as property damage.
In the event, notwithstanding the terms of this agreement,
This book is intended to be a permanent part of your it is determined by a court of competent jurisdiction that
installation and should be preserved in a convenient loca- an express warranty has been given by Seller to Purchaser
tion .for ready reference. If these instructions should with respect to the head, capacity or other Iike perfor-
become soiled, obtain a new copy from Peerless Pump, hance characteristics of said equipment, Seller's liability
include pump model and/or serial number with your for breach of the same shall be limitad to accepting return
request. of such equipment F.O.B. plant of manufacture, refunding
any amount paid thereon by Purchaser (less depreciation
WARRANTY at the rate of 15% per year if Purchaser has used equipment
more than thirty (3W days and cancelling any balance still
New equipment manufactured by Seller is warranted to be
owing on the equipment.
free from defects in material and workmanship under
normal use and service for a period of one year from date THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY
of shipment; Seller's obligation under this warranty being OTHER WARRANTIES, EXPRESSED OR IMPLIED, AND
limited to repairing or replacing at its option any part SELLER SPECIFICALLY DISCLAIMS ANY IMPLIED
found to its satisfaction to be so defective provided that WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE.
Important Safety Precautions

Pump parts, tools and lifting equipment used in installing
or repairing pumps are heavy and may easily cause personal
injury if dropped or carelessly handled. The normal precau-
tions and safety rules with regard to manual lifting, use of
power equipment, and handlin:, of tools must be observed
in the installation, service and repair of this pump.
Petroleum-base cleaning soivents are flammable. Smoking

by personnel in the vicinity of these solvents is extremely
hazardous and must not be permitted.
Do not work under a heavy suspended object unless there is

a positiva support under it to stop its Fall in event of sling
or hoist failure. Disregard of this warning could result in
grave personal injury.
Always take adequate precaution to prevent accidental

running of pump before starting repairs or to remove
pump from base. Start-up during repair or pump removal
could damage pump and may cause personal injury.
Peerless Pump 4846357

A Sterlinig Company Rey. 12/83
MODEL NUMBER F & F1 Iterni
Description
610AM 1 810AM i 820AM 1025AM No.
2683772 2683769 2683770 2683776 1 Casing 808 80C 800 65A 65B
2655973 2655973 2684006 V1810A 7 Casing Ring 46 6 49 37 22 qg 9 i6 31 40 60 734 14 1 2 32 2.

301 7' 26
2683848 2684183 V17358 2684314 2 Impeller 1
V1773A V1774A V1774A 2678391 73A Casing Gasket
2681278 2681245 2681245 2681242 71 Adapter
2681134 6 Shaft
2691519 14 Shaft Sleeve
1100750 16 Bearing, I nboard
2669935 18 Bearing, Outboard
2681015 19 Frame
2681602 22 Bearing, Locknut
Impeller Washer át re
2685768 24A
2685766 26 Impeller Lockscrew
V2343A 32 Impeller Key
2681017 37 Bearing Cover, Outboard
2691534 130 Shaft Sleeve 0-ring
2675921 40 Deflector
V2377A5 46 Coupling Key
2681122 49 Bearing Cover Seal, Outboard
2681123 51 Grease Retainer, Inboard
2687626 80 Mechanical Seal
Pumped Liquid Temperature Maximum Working Pressure

150 PSIG NOTE: F1025AM & F1.1025AM pumps have
20 — 150°F
165 PSIG ANSI Std. 125 lb. Flanges.
200°F
250°F (maximum allowable) @ 150 PSIG
MAINTENANCE
1 WARNING The pumps described by this manual
FREEZING: Where the pump is installed in an unheated
must not be operated at speeds, location, precaution must be taken to protect the pump
capacities, pressures, or temperatures other than those and pipe lines from freezing. If the unit is to remain idle for
specified for the order. A table of temperature — pressure long periods during cold weather, the pump must be
limitations is reproduced aboye. drained by removing the drain plug in the bottom of the
These pumps must not be used to pump any fluid other casing (11.
than that specified for the order. Liquids to be pumped LUBRICATION (F & F1 models only): Use grease, Lithium
must be non-corrosive and non•abrasive or damage can soap base, worked penetration, meeting National Lubri-
occur to pump. For pumps with mechanical seals, liquid cating Grease Institute, Grade 2 specifications. Minimum
pumped rnust not contain hydrocarbons or mechanical seals dropping point 355°F., minimum operating temperature
will be damaged and cause pump failure. range of -10° to 240°F.
Violation of this warning Will void the warranty and may Apply as folÍows:
result in serious property damage or grave personal injury. 1. Thoroughly clean grease fittings and outside of bearing
housing.
INSTALLATION 2. Inject clean new grease. ALWAYS GREASE SPAR-
INGLY.
PIPING: The suction vid discharge piping should not be
3. Start and run pump for a short time to eject any excess
smailer than the inlet or outlet connections of the pump.
Brease.
The piping should be arranged to avoid an excessive number
4. Wipe off VI ejected grease.
of elbows, tees and other fittings. Avoid pockets and loops
in the suction line. Be sure the suction connections are tght 5. Use the following as a guide for the frequency of lubri-
cation.
because air leakage can cause a reduction in pump capacity
Service Grease Each
or ioss of prime.
Normal, 8-hour day operation. Room 6 months
Make certain that the pump is free from
CAUTION free of dust and damaging atmosphere.
piping strains which may cause misalign-
ment, resulting in a possible binding of the rotating eiement. Severe, 24-hour day operation. Room 1 month
Avoid springing the pipe into line and use caution when with moderate dust and/or damaging
tightening the connections. Provide a suitabie means atmosphere, or outdoor service.
other than the pump) to support the weight of the suction
Light, approximately 10-hour week. 1 year
and discharge piping. It is important, particularty in new
pipe linea, that the piping is properly cleaned of all foreign Room relatively free of dust and
material. damaging atmosphere.
2
4846357
PUMP REMOVAL CLEANING
Separate pump from base in the following manner:
in1:11111:.
11 Always take adequate precaution to WARNIN.
G Petroleurn-base cleaning solventa
prevent accidental running of pump are flammabfe. Smoking or open
before starting repairs or to remove pump from base. Start• fleme: in the vicinity of these solvent: is extremely hazard-
up during repairs or pump removal could damage pump and ous and must not be permitted. Disregard of this warning
may cause personal injury. could result in grave personal injury.
1. Open the disconnect switch to cut off power to the
driving device. Temporarily be switch open and attach Clean all metal parts (except bearings) with a solvent. Use a
note: DO NOT CLOSE SWITCH - PUMP REPAIR bristle brush (not metal or wire) to remove tight(y adhering
IN PROCESS. deposits. A fiber scraper may be used to remove the gasket
2. Close valves in suction and discharge lines. and shellac from casing flanges. flow dry with clean com.
3. Remove plug from bottom of casing (1, Figure 1) and pressed air.
drain casing.
4. Disconnect suction and discharge lines.
5. Disconnect flexible coupling or remove belts and CAUTION Never use oil or solvent to clean mechani-
pulley (if used), and coupling key (46). cal seal parts. Use of oil or solvent will
6. Remove frame hold-down bolts and move pump to deteriorate material used for manufacture of the seal.
bench for disassembly.
1. Clean seal parts using a mild soap solution. Rub Only
PUMP DISASSEMBLY; F & Fi MODELS with finger to remove dirt. Rinse with clear water and
dry with mild air stream. Use care not to damage or
Disassemble the pump in the following manner:
scratch lapped surfaces.
1. Take out all screws and remove casing (1) and casing 2. Clean ball bearings in the following manner (F & F I
gasket (73A). If necessary, lightly tap with plastic modeis only):
hammer at several places to loasen casing from adapter. a. Place bearings in wire basket - so there is space for
2. Insert a rod of suitable diameter into a passage of im- cleaner to reach all parts,
peller (2) and ho(d while loosening impeller lock screw b. Immerse in Stoddard solvent. Agitate basket until
(26). Remove lock screw and impeller washer (24A). grease is thoroughly loosened and can be fiushed
3. Slide impeller from end of shaft (6) and remove im• out.
peller key (32). If impeller is hard to remove, use a c. Place bearing on a screened surface.
small wood block against adapter and pry carefully at d. Using a spray gun with air filter and clean Stoddard
several points around impeller to loasen. solvent, flush each bearing until all grease and sludge
4. For the mechanical seal pump, very carefully remove is removed.
seal parts (80A thru 80D). 8e particularly careful not e. 81ow solvent out of bearings with dry, filtered air.
to scratch or damage lapped surface of sealing washer f. Lubricate bearings immediately after cleaning with
(80D). Store seal parts in suitable container; lapped light spindle oil and place them in a covered con.
surface of sealing washer must be up and covered. tainer,
5. Remove screws and sbide adapter (71) off from shaft. g. Do not spin bearings any time during cleaning,
Use care not to scratch shaft sleeve (14). 3. Bearings not removed from the shaft may be cleaned in
6. Carefully push floating seat (65A) from adapter, the following manner:
avoiding scratching or other damage to lapped surface. a. Flush with Stoddard solvent until al( old grease is
Use narrow, fíat screwdriver to lift and work 0-ring removed. Rotate bearing slowly (by hand) while
(65B) from seat. Store seat with remaining mechancial flushing. DO NOT use kerosene or fuel oil for
seal parts with lapped surface up and covered. flushing.
7. Slide shaft sleeve (14) and deflector (40) from shaft. b. Relubricate (refer to paragraph 2, step f, aboye).
Remove 0-ring (130) from shaft sleeve.
8. Remove screws and slide outboard bearing cover (37)
from shaft. Push outboard bearing cover seal (49) INSPECTION
from cover.
9. Push shaft (6) with bearings (16, 18) from frame (19). Visually inspect parts for damage affecting the service-
Push in direction of motor coupling or belt pulley. ability or sealing. Emphasize inspection of mating parts
10. Carefully push inboard grease retainer (51) from frame having relative motion - casing rings, for example. Per-
(19). form detailed inspection as follows:
11. lf bearings (16, 18) are to be removed from shaft, 1. Check O-rings, gaskets, and seals for shrinkage, cracks,
temporarily install impeller key (32) and impeller (2) nicks or tears.
on shaft. With rod inserted into impeller passage, re- 2. Mount the shaft between lathe centers. Check the ec-
strain shaft while loosening bearing locknut (22). centricity throughout the entire length with a dial indi-
Remove locknut, impeller and key from shaft. Sup- cator to be not more than 0.003 inch total indicator
port bearings on inner races and press shaft out. reading. Surfaces on which bearings mount must be
12. Remove casing ring (7) from casing only if damaged or smooth, have a finish not less than 32 micro-inches and
worn ro excess (refer to Repair). the shoulders square and free from nicks.
4846357 3
Peerless Pump
A Sterling Company
PRINTED IN U.S.A.
4846357
Rev. 12/83
3. Examine impeller passages for cracks, dents, gouges CAUTION Use care not to mar or scratch the lapped
or embedded material. surfaces of floating seat and sealing
4, Inspect shaft sleeves (14) for excessive wear. Replace washer when installing mechanical seal. Damage to there
sleeves that are worn. surfaces will result in leakage and will require replacement
5. Inspect lapped surfaces of sealing washer and ffoating of the entire sea).
seat for chipping, gouges, nicks, scratches or other
damage. These surfaces must be free from any defect.
3. For mechanical sea) pump, lubricate the 0-ring (65B),
If lapped surfaces are damaged, replace the entire sea).
groove in floating seat (65A) and seat cavity in adapter
(71) with any of MOLYKOTE® DC No. 55, silicone
REPAIR grease, 3% detergent solution, glycerine or ethylene
glycol.
Remove burrs, nicks and scratches, from non-critical areas,
4. Insta)) floating seat in the adapter with lapped surface
with a fine stone or crocus cloth.
facing away from adapter shoulder. Apply lubricant
1. Impeller and Casing Wear. If the pump capacity falls
(step 9 aboye) to entire surface of shaft sleeve and care-
off due te wear on the impeller and casing ring, repair
fully insta)) adapter. Use care not to cock or scrape
is made by replacing the casing ring. The inside diame-
floating seat on sleeve. Seat adapter against frame,
ter of the casing ring should be 0.008" to 0.012"
tapping very lightly with plastic hammer, then insta))
larger than the impeller skirt diameter.
screws and tighten uniformly. Rotate shaft by hand to
2. Normally, when the pump is completely disassembled,
check that there is no binding or hang-up.
ail gaskets, 0-rings and seals (grease retainer) should be
5. In the same manner as in step 9, lubricate the entire
replaced at reassembly. If the 0-rings for the floating
surface of shaft sleeve and the bores of sealing washer
seat of the mechanical sea) or shaft sleeve are not
(800) and spring bellows assembly (80C). Carefully
damaged, they may be reused with the other satis-
install sealing washer, lapped surface toward floating
factory sea) parts.
seat and spring bellows assembly on shaft sleeve and
REASSEMBLY; F & F1 MODELS s)ide along to contact floating seat. Install spring (808)
and spring retainer (80A), if used.
Reassemble the pump in the following manner: 6. Instan impeller key (32) in shaft keyway. Make sure
1. If bearings (16, 18), Figure 1) were removed from shaft that key enters slot in shaft sleeve. Align impeller (2)
(6), support shaft and press bearing on, applying force with key and install on shaft. Tap impeller hub lightly
only against inner race. Be sure that inner races bottom with plastic hammer to seat against shaft sleeve. For
on shaft shoulders. the mechanical sea) pump, guide the spring retainer
2. Temporarily install impeller key (32) and impeller (2) and spring to seat on the shoulder as impeller is in-
on shaft. Use rod inserted in impeller passage to stalled. Be sure spring is correctly seated against
restrain shaft while tightening bearing locknut (22). bellows assembly.
Remove impeller and key. 7. Insta)) impeller washer (24A) and impeller lock screw
3. Install new inboard grease retainer (51) in frame (19). (26). Restrain impeller with rod inserted in one passage
Lip of retainer, which contacts shaft, must face away and secure)y tighten screw. Rotate shaft by hand to
from inboard bearing (16) cavity. check for free movement.
4. Lightly pack each bearing with a recommended grease 8. Lightly coat both sides of casing gasket (73A) with a
from the instruction, Lubrícation, in this manual. nen•hardening sealing compound such as grease and
Maintain absolute cleanliness at all times while packing graphite. Position on adapter, making sure that holes
and handling bearings. No further lubrication is neces- are aligned. Insta)) casing (1), tapping lightly with
sary until normal maintenance interval is reached. plastic hammer to seat on adapter. Insta)) screws and
5. Coat shaft at inboard bearing (where grease retainer tighten uniformly in a star pattern. The cap screws are
will contact) with light oil or grease. Carefully insert SAE Grade 5 and are to be tightened to the following
shaft through outboard end of frame, impeller end minimum torque va)ues for dry threads.
first. Carefully guide through inboard end and through
Size Torque
grease retainer (51). Push shaft so that retaining ring in
3/8 30 ft - lbs
outer race of outboard bearing (18) contacts frame.
7/16 50 ft - lbs
6. Insta)) new outboard bearing cover sea) (49) in out-
board bearing cover (37). Be sure that sea( lip will face
away from bearing when cover is installed.
7. Coat outboard end of shaft with light oil or grease up
to bearing locknut. Carefully s)ide cover and sea) on ® Trade Mark Dow Corning Corporation
shaft so that lip remains facing away from bearing, posi-
tion so that grease fitting is at top and bottoms against
outer race of bearing. Instan screws to hotd cover, tight-
ening uniformly (do not tighten so that cover is bowed).
8. Instan 0-ring (130) in shaft sleeve (14). Instan deflec-
tor and shaft sleeve over shaft, making sure sleeve
bottoms on shoulder. Position deflector midway Be-
tween end of sleeve and grease retainer. Align sleeve
slot with key slot of shaft.
4 4846357
REASSEMBLY; FO-510M MODEL
MODEL NUMBER FO-510M
Reassemble pump in the following manner:
I6A If bearings (16, 18) were removed from shaft (6), sup-
1.
port shaft and press bearings on, applying force only ---
46 40 18 6 19 16 40 65-80 71 ; 73 2
against the inner race. Be sure inner race bottoms on
shaft shoulders.
Carefully Insert shaft through pump end of trame,
2.
coupling end first. Push shaft so that shoulder of pump
end bearing contaos shoulder in frame bore. Insta)) snap
ring (16A) in proper groove in frame bore. Instan deflec-
tors (40) over shaft ends.
Lubrícate the 0-ring (65B) of the mechanical sea) float-
3.
ing seat (65A) and the seat cavity in adapter (71) with
any of MOLYKOTEO OC No. 55, siticone grease, 3%
detergent solution, glycerine or ethylene glycol.
4. Instan floating seat in the adapter with the lapped sur-
face facing away from adapter shoulder. Appty lubri-
cant (Step 4 aboye) to entire shaft where seal rides and
carefully install adapter onto frame register, then insta))
screws and tighten uniformly. Rotate shaft by hand to
ITEM PART NO. DESCRIPTION check for free movement.
1 2667984 Casing 5. Carefully install the mechanical seal cartridge assembly,

' lapped surface toward floating seat.
2 2661717 Impeller Thread impeller (2) onto shaft rotating clockwise (right
6.
6 2690242 Shaft hand thread) while holding shaft.
7 2655490 Casing Ring 7. Instatl 0-ring (73) into groove in case (1) and install case
2661735 Bearing, Inboard onto adapter. Instatl screws and tighten uniformly to
16
2612056 Retaining Ring 10 ft.-lbs.
16A
18 2690812 Bearing, Outboard
19 2690248 Frame
Notice: Materials of construction, specifications,
dimensions, design features, and application infor-
40 V1448A Deflector mation, where shown in this bulletin, are subject to
46 V3219-10 Coupling Key change and/or modification without notice by
71 2659375 Adapter Peerless Pump at their option.
73 2611901 Casing 0-ring

65-802692269 Mechanical Seal
O Trade Mark Dow Corning Corporation

PUMP DISASSEMBLY; FO-510M MODEL
Disassernble pump in the following manner:

1. Take out all screws and remove casing (1) and casing
0-ring (130). The impeller (2) is assembled to the shaft
by 7/16.20 R.H. thread. Hold shaft (6) and turn im-
peller counterclockwise for removal. The mechanical
seal (65.80) can now be removed for inspection, service
or replacement. Remove casing ring (7) from casing onty
if damaged or worn to excess. (Refer to Repair.)
2. Remove adapter (71) to bearing frame screws. Remove
adapter. Slide deflectors (40) from shaft. Remove snap
ring (16A) from groove in bearing bore on pump end
side of frame (19). Push shaft with bearings from frame.
Push in direction of pump end. If bearings (16, 18) are
to be removed, support on inner races and press shaft
out.
NOTE: Bearings are sealed type. There is no need for clean-
ing or lubricating.
5
4846357
THREE-WAY
THERMOSTATIC
VALVES
slOiO POJENERGY !NC
rARI NO
1. EMP
slg NO -----
3
1/2" /4" I "
SELF-CONTAINER
OPERATES IN ANY POSITION
NON-ADJUSTABLE • COMPACT
TAMPER-PROOF • HEAVY-DUTY
WIOE RANGE OF TEMPERATURES
RUGGED CONSTRUCTION
REPLACABLE ELEMENT
SIZES %, 1.
1%, 2, 4.
FLUID POWER ENERGY, INC.

W229 N591 Foster Court • Waukesha, WI 53186 • (414) 548-6210
1 1/2" THREE-WAY
THERMOSTATIC
VALVE
MODEL A1530
FEATURES
SELF-CONTA1NED • NON-ADJUSTABLE • TAMPER-PROOF • COMPACT
WIDE RANGE OF TEMPERATURES • HEAVY-DUTY • REPLACABLE ELEMENT
RUGGED CONSTRUCTION • OPERATE IN ANY POSITION
DESCRIPTION
FPE thermostatic valves utilize the principie of

expanding wax, which in the semi-liquid state under- some fluid is diverted to the cooling system. As fluid
goes large expansion rates within a retatively narrow temperature continues to increase, more flow is
temperature range. The self-contained power element diverted, and when in a fully stroked condition,
activates a stainless steel sliding valve which provides all flow is positk,ely directed to the cooling
posítive three-way valve actions. All FPE thermostatic system. FPE thermostatic valves may be used for
valves are factory set at predetermined temperatures; either mixing or diverting applications. In normal
no further adjustments are necessary. A wide range operation fluid temperatures are controlled to within
of temperatures are available for water and oil temp- a few degrees.
erature control applications.

Standard FPE thermostatic valve housings are
On starting, the total fluid flow is in a by-pass made from high quality grey iron castings; however,
mode. As fluid temperature rises to the control range steel and bronze housings are available.
irrti'l 7,,e, 124r Ntr 2:t/Jetz, o n 0 n
í 1 /530 va, ve akear
L.. morwr 744.1a-L. i .11/ 1540 VAt..,* Covee
.2 /o
L, u /560 GAilc'er pa. ~by&
-". i / 1571 Z. o/> _Si 1 .
PAJJ Agr- /1101 e .5 • / /360- a•‘. s.,* t- - 7
-7. 1-
4 /4 o/ L. o cK. rv.4.5*-1 e-I2 - >t,
7 4 /400 CAPJCIZS,v - -11,94.,/ / ./.4
di 1 /330 N. ,... e PL.. re-
PA RT NO. 1540 - C.ARRIES A DAIM

NUMSER INDICATING THE NOMINAL TEMP.
Exe,-/A../ascit A■tr- 4N/27.
34
IIIMIEW MHZ
IMI11~111^
UNIR
SE
1s 52 .11111111111•111~Gi
sW
11111111111~1EIMI ..01~1111
gi 11111111111 1111=1
IMINSWIF?:
1111~~
RUZ
A15301110
WALVE PU>
Low ■N U.S. GALS PER. PPIN.

RECENOPENDEIS PRESSIJRE DROP 11
TO
HOW TO ORDER: Specify Model Number, nominal temperature desired, and housing material.

W229 N591 Foster Court • Waukesha, WI 53186 • (414) 548-6210
W229 N591 Foster Court • Waukesha, Wisconsin 53186 • (414) 548-6220
FPE THERMOSTATIC VALVE

TEMPERATURE RANGES
MODEL A1530 MODEL A2010 6 A2010-1

NOMINAL TEM? RANGE NOMINAL TEMP RANGE
80 70- 88 75 70-85
90 80-100 90 85-105
110 100-120 105 100-116
120 110-130 120 110-130
130 120-140 130 124-140
140 130-150 140 135-150
150 140-160 150 145-160
160 150-170 155 150-165
170 163-180 160 155-172
175 170-185 165 160-175
180 175-190 170 165-180
190 185-200 180 175-190
200 190-210 195 188-208
210 200-215
MODEL A1010, A1110 & A1210 MODEL A3010, A4010 & A6010
NOMINAL TEMP RANGE
80 70-88 Same as A2010
95 80-100
110 100-120
120 110-130 HOW TO ORDER - ELEMENTS ONLY
130 120-140
140 130-150 A1010 1060-Nominal Tenp
150 140-160 A1530 1560-Nominal Temp
160 150-170 A2010
170 163-180 A3010 2050-Nominal Temp.
185 175-190 A4010 •?
195 185-200 A6010
200 190-210
/YPICAL 1.--J4e7 NP
A lOi0 W3 1(00
!/ ✓E EP
LVE PI P5 00 NoLE
2') onY FL6 E- J'a& Ji z E-2 ni
M. livc-i-lis
/2/O W3
/ / 0 3/4
/010
1530 1 P2.
20/0-1 12 NoTE!
o 1./74 c 7 20/ O 2 N cJ /kg tb E- R. fizaLcu4.//".4
F,.c -TokzY vk/ w.DEN/07.5 ilzt
Fc,42.
40 1 0
//Al
5 PE /(4 L_ v z S 0, cm/.
/11-Z ‘_J/ D Po t. 4.JE-Q_ EN e la /N c" .

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W229 N591 Foster Court • Waukeshd, Wisconsin 33186 • (414) 548.6220
?PE THERNOSTATIC VALVAS
Your FPE Thermostatic Valva has been manufacturad with extreme

care and tested to insure that it had no detectable defects at
the time it left the factory. If the valve is correctly applied
and installed it will give years of service under reasonable
operating conditions. This instruction manual will give you
service information for nearly all normal operating conditions,
but for unusual situationa it may be necessary to contact your
FPE representative or the FPE factory.
Al]. FPE valves the "expanding wax" type of temperature sensing

element. These elements are set to their nominal rating under
closely controlled conditions, and cannot be altered once they
are set. If it is ever necessary to change the nominal rating of
a valve, a different set of elements must be used.
INSPECTING TSE VALVE ON ITS RECEIPT
Immediately on receiving your valve, check it over carefully for

damage received in shipping, and to be sure you have received the
proper unit. In checking the model number of the valve against
your order you may find that the nominal temperature rating is
stamped below the part number, which is not how it was ardered.
This numbering system merely aliows us to identify the
construction and thermostat setting on a more exact basis. If
you have any questions do not hesítate to call the factory or
your representative.
INSTALLATION
FPE valve dimensions are given on an attached sheet, a copy of

which is supplied with each valve order, and which should be
checked against the actual valve on receipt of the order. If
special engineered drawings have been prepared, these drawings
and FPE standard instructions should be resolved before the valve
is put into service.
on Page 5 of this bulletin are several recommended methods of
applying FPE valves. In general, a "diverting" system wíll
provide a slightly more even temperature control that a "mixing"
arrangement. This is because the former introduces a homogenous
fluid to the sensing elements whereas a mixing system requires
the fluid at two different temperatures to mix in the small
volume of the valve.
If severe electrolysis is expected or encountered in the system,
valve
a zinc or magnesium waste plug should be installed in the
direct sea
at the A port - or as close as possible to it. For
water cooled installations, bronze valves must be used. Cast
Iron housings are not generally satisfactory on sea water.
Page 2

W229 N591 Foster Court • Waukcsha, ly_onsin 53186 • (414) 548-6220
If the valve is mounted at the high point of any system, be sure

that the systems is properly vented to prevent trapping air at
the elements. A good rule to follow on systems is to place air
vents at all high points and drains at all low points. Vents can
all be connected to a single collection point if feasible (as
shown in figure 1, page 5.
OPERATION
After initially placing the valve in operation, system

temperatures should be closely watched to be sure that all
portions of the circuit are performing properly. A system in
which the valves have been properly selected for the anticipated
flows and heat rejection retes should operate very close to the
valve nominal temperature rating. Water cooling systems 'will
usually operate at or slightly below the nominal temperature.
Lubricating oil or other viscous fluids with lower specific heats
than water will indicate at or slightly aboye the nominal
temperature.
The assembled-unit type of construction of the FPE elements makes

it easy to check them if they are suspected of causing erroneous
system operation. The following procedure will give you an
indication as to whether the element is close to its proper
calibration. (For an accurate test we suggest the elements be
shipped prepaid to FPE for checking in our calibrated test tanks.
Note: Whenever shipping elements, be sure to wrap them
individually for protection against nicks and bumps.)
On all elements, the sliding valve starts to lift off the spider
seat at the temperature rating stamped on the side strap. (this
is the only number referencing temperature on the element. All
others are production control numbers.) At 20°F aboye the start
to open temperature, the elements is at or near its full stroke.
(the full stroke temperature varíes from element to element.
Check with a factory representative to be sure.)
Place the element in a bucket of water 5°F below the temperature

rating on the and stir the water vigorously with the element for
5 minutes (the sliding valve should not be off its seat). Next,
place the element in water at 25°F aboye the temperature rating
and stir for 5 minutes. The element should now be fully stroked.
This is determined by immediately placing the element back in the
valve housing, and pushing the element spider fully into it
counterbore. If the resistance of the sliding valve overtravel
spring can be felt, the element if fully stroked. Perform the
last step quickly before the element has cooled, and DO NOT USE
OIL AS THE TEST BATH. On very high temperature elements, water
and glycol may,be used.
Page 3
)FLU1D POWER ENERGY, INC.

W229 N591 Foster Court • Waukesha. N.k isconsin 53186 • 1414) 548.6220
MAINTENANCE
FPE thermsotatic valves probably require leas maintenance than

any other type for similiar use. Elements in normal service
should be good for 6 to 10 years. Excessive temperatures,
chemical, electrolytic or cavitation attack will of course
shorten the life of the elements and seats (which are
replaceable). A teflon seal rather than a Buna-N-0-ring is used
to seal the element. No swelling will occur due to water
additives or synthetic base lubricante.
Carbonates, scale and other solide must not be permitted to build

up on sliding valve or senaing cup surfaces. The valve and
elements may be cleaned with a mild acid or Oakite solutions.
Hard scale may require wire brush buffing. Unless definite
trouble is encountered in operation, a valve need not be
inspected more than every 2 to 3 years. When ordering
replacement parta for FPE valves, always give the item number,
name of the part, the complete valve model number and the correct
serial number.
FPE does not recommend that a large stock of apare parta be
maintained at the valve installation. Most commonly used
elements and seals are immediately available from FPEs' stocking
anea representatives, or from the factory direct. Rubber seats
and composition gaskets are rated for a she]f life of one year
from date of shipment. If adequately sealed from air, they may
be good for longer periods. Shelf life of the FPE elements is
from one to two years, depending on storage conditions.
TROUBLE SBOOTING
In the event that your cooling system does not operate Glose to
the desired temperature, the following check list may Point to
one or more causes for the problem.
1. SYSTEM TEMPERATURE TOO COLD:

A. Insufficient heat rejected to coolant to maintain
temperature.
B. Wrong nominal temperature selected.
C. Bi-metallic type thermometers will indicate low when
calibrated in oil, then used in water.
D. Thermostatic valve greatly oversized or cooling
capacity of system much greater than required.
E. Thermostatic valve iristalled backwards, forces water
to the cooler at lower temperatures.
F. Worn Teflon Seal
G. Too great a pressure difference (in excess of 25
psi) between valve porte.
H. Foreign material stuck between sliding valve and
seat.
Page 4

W229 N591 Foster Court Waukesha, isconsm 53186 • (414) 548-6220
2. SYSTEM TEMPERATURE TOO HOT:

A. Cooling capacity of system not adeqaute.
B. Thermostatic valve too small for flow rate (also causes
high pressure drop and possible cavitation).
C. Valve installed backwards--as temp. increases, B port
cloaca, reducing flow to cooler.
D. Bypass will not close due to worn or pitted seats,
sliding valve, teflon seal, etc..
E. Solids build up on element sliding valve, prevents proper
action of element.
F. Foreign material stuck between sliding valve and seat.
G. Excessive pressure differential between ports (very low
pressure through bypass leg--very high pressure in
cooler).
3. ADDITIONAL ITEMS THAT MAY BE CHECKED ARE

A. Thermometers--A thermometer that reads the same whether
system is cold or hot, needs replacing.
B. Location of thermometers--On horizontal pipe runs, there
should be in the side of the pipe when possible.
(Particularly on oil systems.)
C They should be as far as possible downstream from the
confluente of two streams of different temperature.
D. Look for bypa• sses or "sneak circuits" which prevent
thermostatic valve control of the complete system.
E. Cracked or broken valves may be due to trying to make up
piping runs that are too short; using small ring type
gaskets on fiat face cast iron flanges and pulling bolts
too tight; lack of expansion isolation between valve and
piping; excessive weight or mis alignment of piping;
allowing untreated water to freeze in the systems.
rirdildu
1
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041.. 2
COOUNO WATER CONTROL—!ADATO!
COOUNO WATER COME-ROS— MUT EXCIAMOIR
Vetee 41~ id -1~1- Odsdisos te ~net ~Me nem.
Vette shown M "divertid" iewsolonon. ~mg *eine os
eenoisiole In donen/ lownWn. .W w° 04"W show. in ~Mol posinen leo "minino - hisosiiiconiass.
iwke s.**, te ossoine.
WATER
'Nur
FOOT YA LSI
REOUIRED WHEN
WATER ENGINE P/PING
PUMP 15 LOCATED ASOVE
WATER UNE
041. 3 ri11. 4
DIRECT COOLIING WITH RAW WATER II410`F OR tESSI LUIR OIL CONTROL
Vale shown in divornne position ro control oil tenso
',ohm shows in "diesinine - instoilonon Monos) volee os
slwy..n in donen position les •• moziole .. oses4Wsdione lensperat,ro In dotted patinen, volee wiY - fflis" to tan.
Ind ail Iff"P•fetYfir ro hearings o. nsoniloId.
'VENT --m.. -.SURGE

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777
MeV' ht•VE POSITIVE
Lo.. THERANOSTAT
HtAD ON iNIET
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—1 \I
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FI. 5 fig. irs
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11~ EXPANSION
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WATER SAVING APPUC.ATICM5

Yeshw ot shows wonsioins winonew Iloni *donen
epOltr ro conserve water, rirgy..•1 ifoWnel Isak WATER PUMP
1,01, "D Oortrit ,.,o4111~ 101 sentmg.
P0!? ILOCKED
Is.vi
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NEAT
EXCH.4NOti
• DOITED 'ORAR Und5 TO Y, DePRAIDONG URCIN INSTALLATION AND POUTRA~ Sin

45-s L -Tt.)ba
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REPAIR INSTRUCTIONS POR THERMOSTATIC VALVE MAINTIENANCE XIT
ELEMENT TESTING
PLACE ELEMENT íN WATEVAT A TEMPERATURE 15°F. to 20°F..ABOVE ITS NOMINAL

SETTING AND STIR WATER VIGOROUSLT WITH THE ELEMENT POR FIVE MINUTES. TEZ
TEMPERATURE STAMPED 014 TIE SIDE OF THE ELEMENT IS NOT THE NOMINAL TEMPERA-
TURE, IT IS THE TEMPERATURE Al' WHICH THE ELEMENT IS SET TO OPEN. TEZ
NOMINAL TEMPERATURE IS VSUALLY 10°P. TO 15°F. RIGHER TRAN THIS NUMBER AND
THE FULLY OPENED TEMPERATURE IS APPROXIMATTLY 100F. EICHER TRAN THE NOMINAL.
AFTER STIRRING VIGOROUSLY IMMEDIATELY PLACE THE ELEMENT IN THE HOUSING. IP
THE ELEMENT IS FULLY STROKED, THE SEATING AND OVER-TRAVEL SPRING CAN BE FELT
AS IT IS PUSHED DOWN. TO DETERMINE IF THE ELE4ENT WILL CLOSE AT A SPECIFIC
TEMPERATURE, PLACE 11 ELEMENT IN A BATE OF WATER APPROXIMATELY 5° BELOW
THE START TO OPEN TEMPERATURE. THIS IS THE NUMBER STAMPED ON THE ELEMENT.
DUE TO THE EFFECT OF HYSTERIS THE ELEMENT WILL CLOSE 5° BELOW THE START TO
OPEN TEMPERATURE.
ELEMENT REPLACING
REMOVE FOUR CAPSCREWS (8), LOCKWASHERS (9) AND SEPARATE HOUSINGS REF. (2)
AND (7). REMOVE ELEMENT ASSEMBLY (5) AND SEAL (4). REMOVE HOUSING GASKET
(6). CLEAN HOUSING SECTIONS, REMOVE ANY SCALE OR FOREIGN MATERIAL FROM
SEAL FACES. LUBRICATE NEW ELEMENT SEAL (4) AND SLIDE IN PLACE OVER TOP OF
ELEMENT ASSEMBLY (5) INTO POSITION SHOWN IN SECTION VIEW. PLACE NEW
HOUSING GASKET (6) IN RECESS OF UPPER HOUSING (2). INSERT ELEMENT (5) INTO
UPPER HOUSING (2) TO POSITION SHOWN IN SECTION VIEW. PLACE LOWER HOUSING
(7) OVER EXPOSED SECTION OF ELEMENT (5) AGAINST FACE OF UPPER HOUSING (2).
SECURE HOUSINGS WITH CAPSCREWS (8) AND LOCKWATRERS (9).
SEAL TYPE
#4, REF.
9 NO. DESCRIPTION
1•14,2 2 UPPER NOUSING
RING 3 sLIPA
*4 •0' RING OR LIP SEAL
" +43 ELEMENT ASSEMBLY
*6 GASKET -...
7 LOWER HOUSING,
o W/LIP SEM.
8 CAPSCREW
0 9 LOCKWASNER
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COOPER
ENERGY SERVICES
NOTICE:
Cooper Energy Services attempts to fumish performance curves
and/or design performance computer printouts in this manual to
assist you in compressor operation. If they have been omitted,
please complete the attached sheet and return to CES and a per-
formance curve Will promtly be mailed. If operating conditions
change beyond the ranges shown on the curves, new curves can
be obtained by contacting your CES Sales Representative.
WARNING!
Improper setting of variable volume pockets, fixed volume pock-
ets, valve unloaders or other unloading devices can result in dan-
gerous operation and possible damage and/or injury to equipment
or personnel. Operating this unit without clearance and unloading
information can result in failure due to overloading, excessive rod
loads or high temperature.
COOPER
th ENERGY SERVICES
Fill out and return to: Cooper Cameron Corporation

Cooper-Bessemer Reciprocating Products Division
1401 Sheridan Avenue
P.O. Box 540
Springfield, Ohio 45505-0540
Attention: Marketing Department
Contract or Register Number
Unit Serial Number
Unit Size
Compressor Cylinder Size
Elevation (Feet)
Ambient Temperature (Deg. F)
Suction Gas Temperature (Deg. F)
Specific Gravity
"N" Value
Design Suction Pressure
Anticipated Suction Pressure Range
Design Discharge Pressure
Alternate Discharge Pressure
In additlon to the aboye data a complete gas analysis should be supplied, if available.
Send performance curve to the following address:

COOPER AJAX PRODUCTS
TD- I201
10-20-78
PERFORMANCE CURVES
Performance curves are plotted for compressors when it is expected

that suction or discharge pressures will vary.
These variations affect the amount of gas which a specific compres-

sor cylinder is capable of handling and also the amount of horsepower
required for compression.
The basic compressor unit is designed to operate at a specific horse-

power load. For instante, a DPC-115 compressor will handle a total
load of 115 brake horsepower and operate satisfactorily; however, if the
compressor is overloaded, increased maintenance and/or premature
failure will result. (NOTE: Total load also includes horsepower to
drive auxiliaries such as cooler fan and water pump.)
For a compressor application with varying pressure conditions, the

ideal arrangement would be to have a different size cylinder for each set of
conditions. Since this is not practical, a cylinder is selected which is
large enough to load the unit at the lowest anticipated suction and discharge
pressure. This cylinder may be too large for some of the other conditions
in which case it is necessary to reduce the cylinder capacity to prevent
overloading the basic unit. Reducing the cylinder capacity is generally
accomplished either by adding clearance or by unloading one end of the
cylinder.
The amount of clearance which mUst be added will vary as pressure

conditions change.
Performance curves show graphically the full load capacity of the

basic compressor unit and the capacity which the compressor cylinder
is capable of delivering. When the cylinder capacity is greater than
the full load capacity, the curve shows what adjustments rnust be rnade
to reduce the cylinder capacity to a point that will not overload the basic
unit.
-1-
EXAMPLE:
The following curve is for an Ajax DPC -115 compressor with an 8"
& 5-1/4" X 11" YKDTB single acting two stage compressor cylinder
eci uipped with a variable clearance pocket. This particular curve is for
700 PSIG discharge pressure and suction pressures from 500 PSIG down
to 25 PSIG. Other pertinent data is listed on the curve.
The curve is divided into three steps. Step # 3 covers suction

pressures from 500 PSIG to 200 PSIG. The cylinder is operated
single stage throughout this range with the variable pocket adjusted as
the suction pressure changes. Single stage operation is accomplished
by removing the discharge valves from the 5-1/4" crank end cylinder
and thus operating only the 8" head end cylinder.
As the suction pressure decreases from 500 to 330 PSIG, the variable
pocket must be closed from 6" open to 4" open, and further closed to
1-1/4" open at 200 PSIG suction pressure. At this point the cylinder
must be convrted to two stage operation by installing the discharge
valves in the -1/4" crank end cylinder thus making it operable. The
variablepocket must now be opened from 1-1/4" to 3-3/4" open when
operating two stage at 200 PSIG. The same procedure of gradually
closing the variable pocket as the suction pressure decreases is
repeated until the variable pocket is fully closed at 67 PSIG suction
pressure.
This operating range of suction pressures, from 200 to 67 PSIG

is designated as step # 2 on the curve.
Step #1 covers operation at suction pressures below 67 PSIG down

to 25 PSIG. In this range the compressor is operating at less than
full load; however, there is no further adjustment since the variable
pocket is fully closed and the cylinder is operating at it's design or
minlmum clearance.
If adjustments are .nade in accordance with Figure B, the compres-

sor will be fully loaded from 500 PSIG down thru 67 PSIG as shown by
the full load curved line on Figure A.
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ADJUSTMENT DATA FIG. 8
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WARNING
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surface and position repiacement stud to same height.
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INGINEERING SALES SERVICE DATA
Engines Pumps
Compressors
ESS—S-801
STEM SEALS FOR VARIABLE CLEARANCE POCRETS
June 30, 198 1
Variable clearance pockets on Ajas co=pressor cylinders are

furniehed with a seal to prevent leakage &round the &tem. This
seal is located adjacent to the *tem Buida en which the :cale is
attached.
A new style of seal has been recently adaptad for Ajas
compressors. This seal works equally well in sweet natural and
aour (R2S) gas nervios. Replacement if acedad will be =ore econom-
ical than with the previous dasign.
The s'al kit consiste of two

doutole 11p rype miele and a PRESSURE
modular thack-vp ring. ft le
designed to cover the f1.111
ring. of prestare conditIone
which w111 be ancountered.
Inatallation procedures are simple, but the follawing

precautions should be taken.
1. Cleanlinses - The :leal and all surtaces which
it contacte during ansembly =ust be cleaned,
then wipsd with a lint-free cloth.
2. Lubrication - Both the seal and ita installation
path muat be lubricated with a compatible lubricant
prior to insertion,
3. Nicka/Cuts Prbtection-Care must be exercised when
installing the seal over the threaded portion ot the
ateo to prevent damage to the ~ling lipa.
4. Orientation Instan seal rings facing the comprenaor
oylinder prensare as shown. The back-up ring is
insertad last to provide protaction against extrusion,
and to set as a shock absorber.
The parí number of this new sial kit is 3M-16741.
This supersedem and replacen 3M-16268 o= 3M-16263-A seal
previously usad in this application.
\Z
MERCER 9100 SERIES
"D" ORIFICE
UV ASME [1113] SAFETY REL1EF VALVES
INTRODUCTION
Mercer Valve 9100 Series Safety Relief Valves are the "State of the Art" in soft seat, high flow
rete, pressure relieving devices. This unique design concept provides the user with the following ad-
vantages:
• HIGH FLOW RATES • EXTENDED SEAT LIFE

• PREMIUM QUALITY • ACCURATE SETTINGS
• LOW COST • LOW BLOW DOWN
AH 9100 Series Valves are built in accordance with the requirements of the ASME Boiler and
Pressure Vessel Code. Capacity ratings were established by testing performed at the National
Board of Boiler and Pressure Vessel Inspectors, Columbus, Ohio.
SPECIFICATIONS
Inlet Valve Size 1/2"FNPT, 3/4" MNPT, 1' MNPT
Outiet Size 1" FNPT
Orifice Diameter .394 IN.
Orífice Area .122 SO. IN
Pressure Ranges 15-4500 PSIG
Temp. Rangos
Standard -20°F TO +400°F
Extended -100°F TO +450°F
EQUIV. ASME SLOPE (90%) 1.83
Flow Coefficient "K" (90%) .818
Weight 4.5 LBS
PARTS AND MATERIALS

nem No. Part Name Standard Materials
1 INLET BASE CARBON ST'L
2 BASE SEAL
3 NOZZLE SEAL VITON
4 NOZZLE STNLS STLNITON
5 800V ASSM DUCT. IRON OR STL
6 DISK ASSM STNLS STL
7 SPRING STNLS STL
8 ADJUSTMENT SCR. STNLS STL
9 GUIDE BUSHINGS CARBON STL
10 0 RING BUNAN
11 LOCK NUT CARBON STL
12 CAP ALUMINUM
13 LOCKWIR E STEEL
14 NAME PLATE ALUMINUM
MERCER VALVE CO. INC.

7211 Northwest 3rd Street Post Office Box 22487 • Oklahoma City, Oklahoma 73127
PhrIna tIC1F-P12 • Z. AX rans 495-8728 • 1-800-833-6402
9100 SERIES
PRODUCT NUMBERING SYSTEM
A specific 91 sedes valve is described by a 11 digit product numbering code as foilows:
BODY TYPE AND MATERIAL
1-WCB Cast Steel SEAT MATERIAL
2-CF8M Cast Stainless Steel 7-Teflon
5- Ductible 'ron 8-Viton
91 - D
INLET & OUTLET COMBINATION
05-1/2" FNPT X 1" FNPT
BASE MATERIAL
5-Carbon Steel
7 AP TYPE
1-Closed Top
SPRING
CODE
11-3/4" FNPT X 1' FNPT 6-Stainless Steel 2-Open Lift Lever Assigned
12-3/4' MNPT X 1" FNPT 3-Packed Lift Lever by
16-1" FNPT X 1" FNPT Mercer
17-1" MNPT X 1" FNPT Valve
ORDERING
To order a Safety Relief Valve , a 11 digit product number must be selected plus desígnation of
a set pressure and any special features such as "Nace Trima.
Inlet & Outlet Combination Seat Material
'Met Base Material Set Pressure
Body Type & Material Service Temperature
SET AIR CAPACITIES Nat. Gas Capacites

PRESSURE 3/8'Orifics 3/8" Orifica
(PSIG) (MIllIon Cu. Ft./Day)
(Std. Cu. Ft. Min.)
15 60 .11
25 78 .14
50 128 .23
75 179 .32
100 228 .41
125 279 .50
150 329 .59
200 430 .77
300 831 1.13
4.00 832 1.49
500 1034 1.85
600 1235 2.22
700 1436 2.58
800 1638 2.94
_
900 1839 3.30
1000 2041 3.66
1100 2242 4.02
1 200 2443 4,38
1300 2645 4.74
1400 2846 5.10
1500 3047 5.47
2000 4054 7.27
2500 5061 9.08
3000 6068 10.88
3500 7075 12.69
4000 8082 14.49
4500 9088 16.30
1,12-9102B
Reviscd 04-00
inurph Catalog Section 15
(00-02-0060)
Level Controls for Scrubbers

11200 Series Patents 3970099, 4505288, 4573489
Model L1200
Float Operated Electric ele CE ** ■ BUOYGLAS' Float Operates to 0.5 Specific Gravity
■ Stainless Steel Models Meet NACE Requirements
and Carry Canadian Registration Numbers
■ Models Rated for 2000 psi (13.8 MPa) [138 bar] Vessels
■ Models Listed for Class I, Division 1 Locations
Model L1200N L1100 and L1200 Series Level Switches
Float Operated Pneumatic These float operated level switches are available in electric and pneumatic models.
They are primarily designed for high level applications but models are available for
low leve!. Electric models are listed for Class I, Division I, Groups C & D hazardous
locations. Models are available in all stainless steel to NACE standard MR-01-75 for
direct exposure to H2S service. These level switches have screw-in connections for
direct installation or an optional externa! float chamber is available for the L1200
series high pressure versions. The high pressure versions of both L1100 and L1200
series are rated for 2000 psi (13,8 MPa) [138 bar] operating pressure. See the
specifications sections of this bulletin for further details.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
Model L1200NDVOR L1200NDVOR series carry Canadian Registration Number 0F1476.2.
Float Operated Pneumatic with Dump Valve
Application: L1100 and L1200 Series
Operator, Pressure Regulator and Gage Designed primarily for gas compressor scrubber level. Low pressure models can be
used anywhere level switching of a non-pressurized vessel is required. Electric models
are typically used for high levet shutdown of the engine or electric motor, while
pneumatic models operate vessel dump valves such as Murphy DV-series. Models
designed for low level switching have been used for fuel, lube oil, hydraulic oil, etc.
DV Series Dump Valves

The DV2100, DV875 and DV850 are pneumatically
controlled dump valves. These valves open and close
automatically by pneumatic control from an L1200NDVO or
similar dump valve operator. Diaphragm actuated, the DV series
valves operate at 30-70 psi (207-483 kPa) [2.07-4.83 bar] with up DV875
to 2000 psi (13.7 MPa) [137 bar] vessel pressure. A pop up button Dump
indicates valve open/closed. Va/ve
Model L1200NDVO Primarily engineered for compressor scrubbers, these valves can be applied to any liquids
Float Operated Pneumatic with Dump Valve dumping job that is compatible with the valves materials, pressure limit and flow rates.
Operator NOTE: Ml stainless steel versions of DV850, DV875, and DV2100 series carry
Canadian Registration Number 0C1476.2.
SLS99 MURPHYMATICs Scrubber System

A complete MURPHYMATIC' system for automatic level control of condensate in
scrubbers, including periodic dumping and high level shutdown, is available as a
complete package from Murphy. All wetted metal parts are electroless nickel plated or
stainless steel. The SLS99A scrubber system includes:
(1) DV850 MURPHY NU-MATICTm Dump Valve*
*DV875 and DV21130 dump valves are also available for this system (see page 4). (1) L1200NDVOR MURPHY NU-MATICE Dump Valve Operator which
See page 2 for system operation. includes a Filter/Regulator and MURPHYGAGE'
* *Products covered by this bulletin comply with EMC Council directive (1) L1200 High Level Shutdown switch
89/336/EEC regarding electromagnetic compatibility except as noted.
Specifications L1100 L1111 L1150 L1200 L1250 L1200N L1200NDVO L1200NDVOR
Body
• Standard: Electroless Nickel plated steel ii A gA ir aB 11 8 111 8 Il8 E8
• Optional: 316 Stainless Steelt gA ii A aA 11 El 18 II 8 II8 Il 8
Pressure Rating
• 15 psi (103 kPa) (1.03 bar] Polyethylene Float
• 1500 psi (10.3 MPa) [103.42 bar] Stainless Float i
• 2000 psi (13.8 MPa) [138 bar] BUOYGLASTM' Float
Temperature Rating
• Standard: -20/175T (-29/79°C)
• Standard:-20/300°F (-29/149°C)
• Optional: -20/400°F (-29/204°C)*
Specific Gravity
• Standard: 0.5 with BUOYGLASTm float
• Optional: 0.65 with 304 Stainless Steelt
• Standard 0.73 Polyethylene Float
Electrical
• Standard SPOT: 5 A @ 125/480 VAC (see p. 3 for full ratings)
• Optional DPDT: 10 A @ 250 VAC (see p. 3 for full ratings)
Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)
0-Rings: Viton g
Valve: Two-way snap-action vent type
• 1/8 in. (3 mm) orifice wNiton "A" seat
• 1/8 NPT inlet; 1/4 NPT outlet 1
• 30-70 psi (207-483 kPa) [2,07-4.83 bar] operating pressure
Dump Valve Operator: Operates Murphy DV Series
dump valves or similar.
Pressure Regulator/Filter and Murphy 20BPG:
0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge. u
Maximum input 300 psi (2.07 MPa) [20.68 bar].
Operation:
H=For high level, L=For low level
H L H H H H H H
A=1-1/2 NPT =2 NPT t Meets NACE standard MR-01-75 for direct exposure to H2S service. *Not available with DPDT snap-switch.
SLS99 Scrubber System

Patent No. 4505288 If for any reason the condensate continues to rise beyond
• High Level Shutdown • normal dump levels, the L1200 operates the alarm and/or shuts
• High Level Dump Valve • down the equipment.
• High Level Dump Valve Operator • The MURPHYGAGE® and Filter/Regulator on the L1200NDVOR
helps keep the control pressure clean and dry. It also alIows
operator to adjust pressure to recommended level.
Rising Level Shutdown Air Supply Maximum

L1200 (with snap-switch) 300 psi (2.07 MPa)
Minimum control
pressure 30 psi [20.70 bar]
MURPHY NU-MATIC", (207 kPa) (2.07 bar
Hlgh Liquid Level
Shutdown Switch MURPHY NU-MATICTm Dump Valve Operator Electrical
Dump Velve (L1200NDVOR) Conduit
(L1200)
Patent No. 3970099 (DV850/875/2100) Patent No. 3970099
L1200NDVOR
Patent Pending Dump Valve Operator,
Filter/Regulator
with MURPHYGAGE'
SLS99 System Operation
As condensate rises in the scrubber, the float on the L1200NDVOR Union
Minimum controlpressure
rises and trips it's pneumatic valve. The valve opens allowing 30 psi (207 kPa) [2.07 bar]
pressure to enter the dump valve pilot chamber. Once the
pressure enters the pilot chamber it forces the diaphragm and MURPHY NU-MATIC•
Dump Valve: DV850,
valve stem forward thus opening the valve seat and releasing DV875, or DV2100
condensate through the valve stem and out the drain. As the Union
condensate level drops, the L1200N pneumatic valve closes to
shut off the pressure to the dump valve causing it to close. --.-Condensate Out
Dimensions Accessories
11 in.
L1100 (279 mm) Adaptor Bushing 55050617
and (89 mm) for DV850 and DV875
r
2-1/16 in
L1200 (52 mm)
2.3/16 in. See

Note 1: (56 mm) Note 2
L1100: 1-1/2 NPT
L1200: 2 NPT
Note 2: 1-9/16 (40 mm) 1/2 NPT See Float travel between Operate
Note 1 and Reset= 0.25 in. (6 mm).
SF option:
Switch operates on Rising Level
L1100: 1-1/2 (38 mm) 3-5/8 in. 2 NPT
w/ float at horizontal centerline
L1200: 1-3/4 (44 mm) (92 mm) e3.25 in. (6 mm). Material: 2-1/2 Hex bar stock C.R.S
L1111 11-5/16 in. Float Chamber 15050697

(287 mm)
/1 in
7-96
3-53/64 in. 1 NPT (2 places) (192 MM)
(97 mm)
2 NPT
T 1
8 1/2 in.
2.3/16 in. See
(56 mm) (216 mm) 3-1/2 in.
Note
(89 mm)
Hex
Float travel between Operate
Note: 1-9/16 (40 mm) 4

1/2 NPT 1-1/2 NPT
3-5/8 in.
and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
3-1/2 h.
(89 mm)
645/64 in. Material: Cast Steel, WCB
SF option: 1-1/2 (38 mm) wl float at horizontal centerline (170 mm) Canadian Registration Nurnber. 0H1476.2
(92 mm) 80.25 in. (6 mm).
Operating Pressure 2000 psi (13.8 MPa) [138 bar]
Operating Temperature: 400°F (204°C)
L1150 Typical L1200/L1200N Float Chamber Installation
and
L1250
1 Tank
2-3/16 in
(56 mm) 111
1111
Note 1: L1150: 1-1/2 NPT 1/2 NPT Float travel between operate
11250: 2 NPT and reset= 0.75 in. (19 mm).
Switch operabas on Rising leve) w/ float at
Note 2: L1150: 1 -1/2 in. (38 mm) horizontal centenine110.25 in. (6 mm).
LI250: 2 in. (51 mm)
Pressure L1200N, L1200NDVO Weld Collar 15050375

Regulator
11111111 (use with L1200 °n'y)
with 20BPG
Pressure Gaga New Dump Valva
and L1200NDVOR
Operator Assembly
pin 15010216
with Dump 4111/41/41,41/4/ ,41
Valve Operator, 2-7/8 In
1111111111111111
Pressure Regulator (73 mm)
Old Round Dump Valve

Operator Assembly
and Gage 11 1
p/n 15000940 dril///
I 4-1/2 in
(114 mm) Material: ASTM A105-2
3-5/8 in. (92 mm)-- 5 in. (127 mm.) minimum UNS K03504
clearance Is reguired for
3/4 Hex Boa) movement. Typical L1200 Weld Collar Installation
(See Note)
Tank Wall
2-3/16 h. Operating Pressure:
-1-9/16 in. Weld Collar
(56 mm)
1 (40 mm)
$F option=
2000 psi (13.8 MPa) [138 bar]
Operating Temperattre:
1.3/4 in.
(44 mm) 400°F (204°C)
3-1/2 h. (89 mm)
F., 3-3/4 in. (95 mm)
—11 in. (279 mm) SF opdon= 11-1/4 )n. (286 mm) L1200
Note: For use only with Old Round Dump Valva Operator Assembly (15000940).
Wiring DPDT (snap-switch) Float Shaft Extension 15000892

Green Grd. Connection 10-32 UNF
Bleck N.O. o white com.
SPDT (snap-switch)
Red N.C. o—f O
Green Grd. Connection
Blue N.C. O
Bleck N.O. o
White COM. Yellow COM. 10-32 NF
1 /
Orenga
Red N.C.
1 3/8 in 3/8 in
o (35 mm) (10 mm)
Switch Rating: 5 A @ 125-250- 480 VAC Switch Rating: 10 A /8 125-250 VAC Material: AISI 304, UNS-S30400
1/2 A ,11) 125 VDC 1/2 A 41 125 VDC
1/4 A 41 250 VDC 1/4 A ID 250 VDC NOTE: The extension is used with the L1100 and L1200 only. One extension
2A /8 6-30 VOC Resistive 10 A /8 6-24 VOC is supplied with each unit. Use of additional extensions is not recommended
1A /8 6-30 VDC lnductive lnductive/Resistive as they reduce the ability of the unit to operate for the stated specific gravity.
How to Order
L1100 and L1200 Series Replacement Parts (order by part number designation)
--- Build a complete model number using the diagram below. See L1100/L1200
example. See Specifications Chad on page 2 for standard and 15000893: BUOYGLAS TM float
optional features. 15000894: Stainless Steel float for L1200
15000937: Stainless Steel float for L1100
Example model number 15000124: SPDT snap-switch assembly
L1100- 15010213: L1100 counter balance assembly
15010214: L1200 counter balance assembly
Options L1200N
D DPDT 15050420: Cam spring return
K = KALREZ Seals 15050421: Cam
SF = Stainless Steel Float 15000893: BUOYGLASTM float
400 = 400°F (204°C) Service** 15000894: Stainless steel float for L1200N
15050453: Valve stem
15010189: Counter balance assembly
L1200NDVO and L1200NDVOR
Base Models
55050621: Regulator only
L1100* L1100SS 05706499: 20BPG-D-75 psi (0-517 kPa)10-5.17 bar]
L1111 L1111SS 15010216: DVOA assembly (New rectangular style)
L1150 L1150SS 15000940: OVO assembly (Old round style)
L1200* L1200SS* 00003341: Filter for regulator
L1250 L1250SS 00003340: Regulator diaphragm kit
L1200N* L120ONSS*
L1200NDVO* L1200NSSDV0* Shippirig Weights
L1200NDVOR* L1200NSSOVOR* L1100: 6 lb. (2.7 kg).
L1111: 5 lb. 11 oz. (2.5 kg).
*Stainiess steel models carry Canadian Registration Number 0F1476.2. L1150: 5 lb. 4 oz. (2.3 kg).
**Not available with DPDT snap-switch. L1200: 61b. 6 oz. (2.8 kg).
L1250: 6 lb. 6 oz. (2.8 kg).
L1200N: 5 lb. 5 oz. (2.4 kg).
L1200NDVO: 5 lb. 14 oz. (2.6 kg).
Complete SLS99 Systems
L1200NDVOR: 6 lb. 10 oz. (3 kg).
Specify
SLS99: 19 lb. 6 oz. (8.7 kg).
SLS99A: (uses DV850) with 1 NPT
SLS99B: (uses DV2100) with 2 NPT Shipping Dimensions
SLS99C: (uses DV875) with 1 NPT L1100: 14 x 5 x 3-1 /2 in. (356 x 127 x 89 mm).
L1111: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
Accessories (order by part number designation) L1150: 14 x 5 x 3-1 /2 in. (356 x 127 x 89 mm).
15050375: We/d collar
L1200: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
15000892: Float shaft extension L1250: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
55050617: DV850 adaptor bushing 2 NPT-M to 1 NPT-F L1200N: 14 x 5 x 3-1 /2 in. (356 x 127 x 89 mm).
15050697: External Float Chamber (Canadian Registration L1200NDVO: 14 x 5 x 3-1 /2 in. (356 x 127 x 89 mm).
Number 0H1476.2) L1150NDVOR: 10 x 9-1 /2 x 6 in. (254 x 241 x 152 mm).
SLS99: 15 x 15 x 12 in. (381 x 381 x 305 mm).
Warranty
A two-year limited warranty on materials and workmanship
is given with this Murphy product. Details are available on
request and are packed with each unit.
In order to consistently bring you the highest quaW, full featured products, we reserve the right to change our specifications and designs at any time.
FRANK W. MURPHY MANUFACTURER P.O. Box 470248; Tulsa, Oklahoma 74147; USA tel. (918) 627-3550 fax (918) 664-6146 e-mail sales@hrenurphy.com http://swov.ftwurphy.com
FRANK W MURPHY MFR. MURPHY DE MDOCO, S.A. DE C.V. MURPHY SWITCH OF CALIFORNIA
CONTROL SYSTEMS & SERVICES DIVISION Bhrd. Antonio Rocha Cordero 300, Fracción del Aguaje 41343 12th Street West
inurph P.O. Box 1819; Rosenberg, Texas 77471; USA San Luis Potosí, S.L.P.; México 78384 Palmdale, California 93551-1442; USA
tel. (281) 342.0291 fax (281) 341.6006 tel. +52-48-206264 fax +52-48-206336 tel. (661) 272-4700 fax (661) 947-7570
e-mail sales@fwmurphy.com e-mail ventasmexemurphymex.com.mx e-mail sales@murphyssItch.com
http://www.murphyswitch.com
FRANK W. MURPHY, LTD. FRANK W. MURPHY PTE., LTD.
Church Rd.; laverstock, Salisbury SP1 10Z; U.K. No. 2 Tuas South Street 2, MACQUARR1E CORPORATION
tel. +44 1722 410055 fax +44 1722 410088 Sprintecs Bldg., 402-o1/02 1620 Home Highway;
e-mail sales@hvmurphy.co.uk Singapore 638042 Campbellfield, Vic 3061; Australia
USA-ISO 9001 FM 28221 http://vve.fwmurphy.muk tel. +65 863-1398 fax +65 863-0208 tel. +61 3 9358-5555 fax +61 3 9358-5558
UK-ISO 9002 FM 29422
e-mail fwmsaleservanurphy.com.sg murphy@macguanie.com.au
tel. +33 1 30 762626 fax +33 1 30 763989
Pnnted in U.S.A. 0191096
41" FRANK W.
DV-98110B
Revised 11-99
Catalog Section 15
.FR. (00-02-0325)
Dump Va lves
DV Series MURPHY
• For Separators/Scrubbers to 2000 psi (13.7 MPa)

[137 bar] Vessel Pressure
• Unique Positive-Seal, Field-Replaceable
Piston Seal and Body Seat Assembly
DV875 • Operates on 30-70 psi (207-483 kPa)
Patent Pending [2.07-4.83 bar] Control Pressure
• Built-In Valve Open/Closed Pop-Up
Indicator Button
• Compatible with Murphy Level Controls
Description Specifications Dimensions

The DV850, DV875, and DV2100 are pneumati- Operating Temperature:
DV850/SS DV875/SS DV2100/SS
cally controlled dump valves. They open and -30 to +300°F (-34.4 to +149°C)
A 6-3/4 (171) 6-3/4 (171) 6-3/4 (171)
close automatically by pneumatic control from a Valve Operating Pressure: B 7-9/64 (181) 7-9/64 (181) 7-59/64 (201)
Murphy L1200NDVOR or similar level con- 30-70 psi (207-483 kPa) [2.07-4.83 bar] C 3-9/32 (83) 3-9132 (83) 3-63/64 (101)
D 2-19164 (58) 2.19/64 (58) 2-5/32 (55)
troller and dump valve operator. Diaphragm Maximum Process Pressure: E 1 NPT 1 NPT 2 NPT
actuated, the DV series dump valves operate at 2000 psi (13.7 MPa) [137 bar] F 1/2 NPT 314 NPT 1 NPT
30-70 psi (207-483 kPa) [2.07-4.83 bar] and up Stern Seal: Carbon/Graphite Filled PTFE G 1/8 NPT 1/8 NPT 118 NPT
to 2000 psi (13.7 MPa) [137 bar] vessel pressure. NOTE: Dimensions are in inches and (millimeters)
Upper Case Coating: Electroless Nickel Plated
See "Operating Pressures" chart. on 12L14 Carbon Steel,
Murphy offers stainless steel versions of the DV850, • A
Body Material: DV850, DV875, and DV2100: G. Pressure Inlet Port
DV875, and DV2100 Series. Electroless Nickel Plated 12L14 Carbon Steel
NOTE: Al! stainless steel versions carry Canadian DV850SS, DV875SS, and DV2100SS: ANSI
Registration Number 0C1476.2, 316 (UNS3 1600) Stainless Steel
Wetted Paris: Body: 12L14 Carbon Steel.
Operating Pressures Optional ANSI 316 stainless steeL Vent —
Operating yo. Vessel Pressure Valve Open/Closed
70 Shaft/Stem; ANSI 316 stainless steel. F Drain Indicator Button
65 Guidebushing: ANSI 316 stainless steel. Connection
60 Body Seat: ANSI 316 stainless steel.
us 55
a Piston Seal: ANSI 316 stainless steel.
e>
Ñ 45
40 Positive-Seal
o 35
Detail Body Seat D
E 30
D1/8501875
Piston Seal
S 25 0
2000
500 1000 1500
Vessel Pressure (PSIG)
Application
Primarily designed for compressor scrubbers,
these valves can be used to dump any liquids
compatible with the valve's specifications.
Dump Valve Operation >-
As condensate rises in the scrubber, the float on
the Murphy L1200NDVOR rises and trips its
pneumatic valve. The valve opens allowing pres-
sure to enter the dump valve pilot chamber. Once L1200 (y. th snap-switch)
Minimum control 300 psi (2.07 MPa)
the pressure enters the pilot chamber it forces the pressure 30 psi [20.70 bar]
diaphragm and valve stem forward thus opening (207 kPa) [2.07 bar
the valve seat and releasing condensate through Electrical
the valve stern and out the drain (a pop up button Conduit
indicates valve open/closed). As the condensate
L1200NDVOR
level drops, the L1200NDVOR pneumatic valve Dump Valve Operator,
closes to shut off the pressure to the dump valve, Fi lter/Reg ul ator
allowing it to close. with MURPHYGAGE•
OOO Rising
If for any reason the condensate continues to rise
beyond normal dump levels, model L1200 High
111 Level
Trips Union
00000 Minimum control pressure
Level Shutdown Switch operates the alarm 00000 DVO 30 psi (207 kPa) [2.07 bar]
and/or shuts down the equipment.
The MURPHYGAGE® and Filter/Regulator on O MURPHY NU-MATIC°
the L1200NDVOR help keep the control pres- Dump Valve: DV850,
sure clean, dry, and at proper pressure levels for Ball Valve DV875, or DV2100
system activation. Union
NOTE: Always use clean, dry, instrument guality gas.
--0-Condensate Out
SLS99 MURPHYMATIC.
Scrubber Systems
Patent Pending
How to Order Replacement Parts

Specify model number: 55000219: Diaphragm Assembly (all models)
DV850: 1 NPT Process Connection 55000224: Seat Kit (piston seal & body seat)
DV850SSt*: 1 NPT Process Connection for DV850, DV875, DV850SS, DV875SS
Patent 3970099 Patent 3970099 DV875: I NPT Process Connection
Patent Pending
1 NPT Process Connection 55000225: Seat Kit (piston seal & body seat)
DV875SSt*:
for DV2100
A complete MURPHYMATIC® system for auto- DV2100: 2 NPT Process Connection
matic level control of condensate in scrubbers, DV2100SSt*: 2 NPT Process Connection Optional Adapter Bushing
shown aboye, is available as a complete package fAISI 316 Stainless Steel body. 55050617: 2 NPT to 1 NPT
from Murphy. *Stainless steel models carry Canadian Registration
Number 0C1476.2.
The SLS99A Scrubber System includes:
(1) DV850 Dump Valve*
Shipping Dimensions
(1) L1200NDVOR Dump Valve Operator which
includes filter/regulator and MURPHYGAGE® Shipping Weights
(1) L1200 High Level Shutdown Switch DV850 and DV875: 9 lbs (4 kg). Warranty
*The dump valve for the SLS99B is DV2100. DV2100: 13 lbs (6 kg). A two-year limited warranty on materials and workman-
The dump valve for the SLS99C is DV875. Shipping Dimensions (all) ship is given with this Murphy product. Details are avail-
For more information contact your nearest 7 x 7 x 11 in. (178 x 178x 279 mm). able on request and are packed with each unit.
Murphy sales representative or distributor.
in arder to consistently bring you the híghest quality, full featured products, we reserve the right to change our specifications and designs at any time.
FRANK W. MURPHY MANUFACTURER P.O. Box 470248; Tulsa, Oklahoma 74147; USA tel. (918) 627-3550 fax (918) 664-6146 e-mail sales@fwmulphy.com http://www.fwmurphy.com
.-1.1111r
FRANK W. MURPHY MFR. MURPHY DE MFACO, S.A. DE C.V. MURPHY SWITCH OF CALIFORNIA
CONTROL SYSTEMS & SERVICES 8Ivd. Antonio Rocha Cordero 300, Fraccián del Aguaje 41343 12th Street West
P.O. Box 1819; Rosenberg, Texas 77471; USA San Luis Potosi, S.LP.; México 78384 Palmdale, California 93551-1442; USA
tel. (281) 342-0291 fax (281) 341-6006 tel. +52.48.206264 fax +52-48-206336 tel. (661) 272-4700 fax (661) 947-7570
e-mail salesefwmurphy.cem e-mail ventas@murphymex.com.mx e-mail sales@mughyseitch.com
http://rnmmurphyswitdcom
FRANK W. MURPHY, LID. FRANK W. MURPHY PIE., LTD.
Church Rd.; laverstock Salisbury SP1 102; U.K. No. 2 Tuas South Street 2, MACQUARRIE CORPORATION
tel. +441722 410055 fax +441722 410088 Sprintecs Bldg., F02-01/02 1620 Hume HigInvay;
-*en, e-mail salesefvnnurphy.co.uk Singapore 638042 Campbellfield, Vic 3061; Australia
USA-ISO 9031 FM 28221 http://www.fwrnurphy.to.uk tel. +65 863.1398 fax +65 863-0208 tel. +613 9358-5555 fax +61 3 9358-5558
UK-ISO 9002 FM 29422
e-mail fwmsales@hernurphy.com.sg e-mail murphy@macguarrie.com.au
tel. +33 1 30 762626 fax +33 1 30 763989
Printed in U.S.A.
CR- 77 9 7
FORM U-1A MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS
(Attemative Form for Single Chamber, Com_pletely Shop-Fabricated Vessels Only) Form U1-A
As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1
COOPER ENERGY SERVICES 2101 S.E. 18th St. OKLAHOMA CITY, OK, USA 73129-8351
---- Manufactured and certified by
(Name and address of Manufacturer)
ANDINA / BOLIVIA VIBORA,BOIVIA
z. Manufactured for
(Name and address of Purchaser)
UNKNOWN
3. Location of Installation (Name and address)
NIA YK 6660 U 4 3OO8O 2000
4. Type VERTICAL 24V34290 (Nati. Bd. No.) (Year Built)
(CRN) (Drawing No.)
(Horiz. or vert. tank) (Mfgr's serial No.)
5. The chemical and physical properties of all parta meet the requirements of material specifications of the ASME BOILER and PRESSURE VESSEL CODE.
The design, construction, and workmanship conform to ASME rules, Section VIII, Division 1 1998
NONE (Year)
te 1999 NONE
Addenda (Date) Code CaseNos. S ecial Service per UG-120 (d)
2FT, OIN. OD 5 FT. 6 IN.
6. Shell: SA106B .375 NONE
Diam. ID (ft. & in.) Length (over« (ft. & in.)
(Spec. No., Grade) Nom. Thk. (in.) Corr. Allow. (in.)
NIA TYPE 1 NONE 1
7. Seams: SEAMLESS NONE 85 N/A
RT (Spot or Full) Eff. (%) H.T. Temp. (T.) Time (hr.) Glrth (Welded, Dbl., Sngi., Lap, Butt) RT (Spot, Partial or Full) No. of Courses
Long.ffielded, Dbl., Sngl., Lap, Butt)
(b) Mari. SA516-70
8. Heads: (a) Mat'I. SA516-70 (Spec. No., Grade)
(Spec. No., Grade)
Elliptical Conical Apex Hemispherical Flat Side to Pressure
Min. Thickness Corrosion Allowance Crown Knuckle DiameteriConvex or Concave)
Location (Top, Radius Ratio Angle Radius
Bottom, Ends) mm in mm in Radius
2:1 N/A N/A N/A CONCAVE
a) TOP NONE .340 NONE NONE N/A N/A
N/A 2:1 N/A N/A NIA CONCAVE
b) BOTTOM NONE .340 NONE NONE NIA
If removable, bolis used (describe other fastenings)
N/A
(Mat'l., Spec. No., Gr., Size, No.)
260 psi at max. temp. 200 °F
9. MAWP
psi. Hydro., Pneu., or Comb. test pressure HYDRO-338 psi.
Min. design metal temp. -20 °F at 260
10. Nozzles, inspection and satery varee operungs.
Nom. Thickness Reinforcement How Location
Purpose No. Diameter or Size Type Material
Material Attached
(Inlet, Outlet, Drain) mm in
SCH. 40 AVAIL B&D WELD SHELL
*INLET/OUTLET 2 - 8"150 RFWN SA105
3000# AVAIL D WELD SHELL
CONTROL 2 - 2" COUP SA105
SCH. 40 AVAIL B&D WELD NOZZLE
BYPASS 1 - 3"150 RFWN SA105
3000# AVAIL D WELD BOTTOM HEAD
DRAIN 2 r& 2" COUP SA105
6000# AVAIL D WELD SHELL
PRESSURE 3 - 1/2" COUP SA105
SA105 6000# AVAIL D WELD SHELL
GAUGE 2 - 3/4" COUP
SAI05 6000# AVAIL D WELD SHELL
TEMPERATURE 1 - 1" COUP
6000# AVAIL D WELD TOP HEAD
RELIEF VALVE 1 - 2" COUP SA105
t ■ rArN kAlrl 1-1
NO Legs NO Other NIA Attached
11. Supports: Skirt YES Legs
(Describe) (Where and how)
(yes or no) (No.) (No.)
12. Remarks: Manufacturera Partía' Data Reports properly identified and signed by Commissioned Inspectora have been fumished for the following iteres
of the report: N/A (Name of part, 'tem number, Mfgr's. name and identifying stamp)
IMPACT TEST EXEMPT UG-20F.*NOZZLE MATERIAL SA106B. NOZZLE ATTACHMENT WELOS ARE CATEGORY TYPE .
SEPARATOR NATURAL GAS NON-CORROSIVE SERVICE
9797-05
CERTIFICATE OF SHOP COMPLIANCE
at all details of design, material, construction, and workmanship of this ves
We certify that the statements made in this report are correct and
conform to the ASME Code for Pressure Vessels Section VII ion 1. "U" Certificate of authorization No. 5453
expires 08-17 )1034( ,491)/ Signed-
Co. Name: COOPER ENERGY SERVICES
Date: 05-01-00 (Manufacturer)
presentative)
CERTIFICATE OF SHOP INSPECTION

at OKLAHOMA.CITY OK. . I, the undersigned,
Vessel constructed by COOPER ENERGY SERVICES and
holding a valid Commission issued by the National Board of Boiler and Pressure Vessel Inspectora and/or the State or Province of OKLAHOMA
employed by FACTORY MUTUAL INSURANCE CO. JOHNSTON RI have inspected the component described in this Manufacturera Data Report on
05-01-00 , and state that, to the best of my knowledge and belief, the Manufacturer has constructed this pressure vessel in
accordance with ASME Code, Section VIII, Division 1. By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or
implied, conceming the pressure vessel described in this Manufacturera Data Report. Furthermore, neither the Inspector nor his employer shall be fiable
in any manner for any personal injury or property damage or a lo of an kind arising from or connected with this inspection.
Date 741., oón Signe Commissions 199 DK gsr ,.
(Aut •rized Inspector) Nat'I. Board (Incl. endorsements, State, Prov. and No.)
/
(Alternative Form for Single Chamber, Completely Shop-Fabricated Vessels Only)
As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 Form U1-A
. ,.1. Manufactured and certified by COOPER ENERGY SERVICES 2101 S.E. 18th St. OKLAHOMA CITY, OK, USA 73129-8351
(Name and address of Manufacturer)
2. Manufactured for ANDINA / BOLIVIA VIBORA,BOLIVIA
3. Location of Installation UNKNOWN
(Name and address)
4. Type HORIZONTAL 16H34291 N/A YK 6416S 54 30105 2000
(Horiz. or vert. tank) (Mfgr's serial No.) (CRN) (Drawing No.) (Nat'I. Bd. No.) (Mear Built)
5. The chemical and physical properties of all parts meet the requirements of material specifications of the ASME BOILER and PRESSURE VESSEL CODE.
to 1999 NONE NONE (Year )
Addenda (Date) Code Case Nos. Special Service per UG-120 (d)
6. Shell: SA106B .375 NONE 1 FT. 4 IN. OD 6 FT. 8 IN.
Mari (Spec. No., Grade) Nom. Thk. (in.) Corr. Allow. (in.) Diam. ID (ft. & in.) Length (overall) (ft. & in.)
7. Seams: SEAMLESS NONE 85 N/A N/A TYPE 1 NONE 1
Long.(Welded, DK, Sngl., Lap, Butt) RT (Spot or Fun) Eff. ("4) N.T. Temp. (T.) Time (hr.) Girth (Welded, DK, Sngl., Lap, Butt) RT (Spot Partial or Fun) No. of Courses
8. Heads: (a) Man SA516-70 (b) Mari. SA516-70
(Spec. No., Grade) (Spec. No., Grade)
Location (Top, Min. Thickness Corrosion Allowance Crown Knuckle Elliptical Conical Apex Hemispherical Flat Side to Pressure
Bottom, Ends) mm in mm in Radius Radius Ratio Ancle Radius Diameter (Convex or Concave)
a) END NONE .328 NONE NONE N/A N/A 2:1 N/A N/A N/A CONCAVE
b) END NONE .328 NONE NONE N/A NIA 2:1 N/A N/A N/A CONCAVE
1f removable, botts used (describe other fastenings) NONE
(Mat'l., Spec. No., Gr., Size, No.)
9. MAWP 260 psi at max. temp. 200 °F
Min. design metal temp. -20 °F at 260 psi. Hydro., Pneu., or Comb. test pressure HYDRO-338 psi.
10. Nozzles, inspection and safety valve openings:
Purpose No. Diameter or Size Type Material Nom. Thickness Reinforcement How Location
(Inlet, Outlet, Drain) mm in Material Attached
*INLET 1 - 8'150 RFWN SA105 SCH. 40 AVAIL. B&D WELD SHELL
*OUTLET 2 - 6"300 RFWN SA105 SCH. 40 AVAIL. B&D WELD SHELL
11. Supports: Skirt NO Lugs NO Legs NO other FLANGES Attached NOZZLES,WELD

(yes orno) (No.) (No.) (Describe) (Where and how)
12. Remarks: Manufacturer's Partial Data Reports properly identified and signed by Commissioned Inspectors have been furnished for the following ítems
of the report: NONE
(Name of part, item number, Mfgr's. name and identifying stamp)
RELIEF VALVE IN PIPING. IMPACT TEST EXEMPT UG2Of *NOZZLE MATERIAL SA106B.
NOZZLE ATTACHMENT WELDS ARE CATEGORY TYPE. SUCTION HEADER NATURAL GAS NON-CORROSIVE SERVICE,
9797-11B
We certify that the statements made in this report are correct and that a details of design, material, construction, and workmanship of this vesse
conform to the ASME Code for Pressure Vessels, Section VIII, Div" . "U" Certificate of authorization No. 5453
expires 08-17 404 14)( ,„? 0:2/ ,
Date: 05-16-00 Co. Name: - COOPER ENERGY SERVICES Signed:
(Manufacturer)
Vessel constructed by COOPER ENERGY SERVICES at OKLAHOMACITY i, the undersigned,
holding a valid Commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of OKLAHOMA and
employed by FACTORY MUTUAL INSURANCE CO JOHNSTON Ri have inspected the component described in this Manufacturer's Data Report on
05-16-00 , and state that, to the best of my knowledge and belief, the Manufacturer has constructed this pressure vessel in
iccordance with ASME Code, Section VIII, Division 1. By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or
implied, conceming the pressure vessel described in this Manufacturer's Data Report. Furthermore, neither the Inspector nor his employer shall be fiable
in any manner for any personal injury or property damage or al of rising from or connected with this inspection.
DateAp_"_" Signed•Imiai.". 1 Commissions 443 Aailpy,4 cv?
(Au rized Inspector) Narl. Board (Incl. endorsements, State, Prov. and No.)
(Altemative Form for Single Chamber, Complete)y Shop-Fabricated Vessels Only) Form U1 -A
-- -- 1. Manufactured and certified by COOPER ENERGY SER' :CES 2101 S.E.18th St. OKLAHOMA CITY, OK, USA 731295351
(=. le and address of Manufacturer)
2. Manufactured for .-,;‘,11DINA / BOLIVIA VIBORA,BOLIVIA
3. Location of Installation UNKNOWN
(Name and address)
4. Type HORIZONTAL 16H34292 NIA YK6416D46 3 01 0 6 2000
(Horiz. or vert. tank) (Mfgrs serial No.) (CRN) (Drawing No.) (Nati. Bd. No.) (Year Buitt)
5. The chemical and physical properties of all parts meet the requirements of material specifications of the ASME BOILER and PRESSURE VESSEL CODE.
1999 NONE NONE (Year )
to
Addenda (Date) Code Case Nos. Special Service per UG-120 (d)
6. Shell: SA106B .500 NONE 1 FT. 4 IN. OD 6 FT. 8 IN.
Mari. (Spec. No., Grade) Nom. Thk. (in.) Corr. Allow. (in.) Diam. ID (ft. & in.) Length (overall) (ft. & in.)
7. Seams: SEAMLESS NONE 85 N/A N/A TYPE 1 NONE 1
Long.(Welded, Dbl., Sngl., Lap, Run) RT (Spot or Fun) EH. (%) N.T. Temp. (°F.) Time (hr.) Girth (Welded, Dbl., Sngl., Lap, Butt) RT (Spot, Partial or Pul No. of Courses
8. Heads: (a) Mati. SA516-70 (b) Mari. SA516-70
(Spec. No., Grade ) (Spec. No., Grade)
Location (Top, Min. Thickness Corrosion Allowance Crown Knuckle Elliptical Conical Apex Hemispherical Flat Side to Pressure
Bottom, Ends) mm in mm in Radius Radius Ratio Angle Radius Diameter (Convex or Concave)
a) END NONE .328 NONE NONE NIA N/A 2:1 NIA N/A N/A CONCAVE
b) END NONE .328 NONE NONE NIA N/A 2:1 NIA N/A N/A CONCAVE
If removable, bolts used (describe other fastenings) NONE
Spec. No., Gr., Size, No.)
9. MAWP 645 psi at max. temp. 350 °F
Min. design metal temp. -20 °F at 645 psi. Hydro., Pneu., or Comb. test pressure HYDRO-839 psi.
10. Nozzles, ins ection and safety valve o enin s:
Purpose No. Diameter or Size Type Material Nom. Thickness Reinforcement How Location
(Inlet, Outlet, Drain) mm in Material Attached
*INLET 2 - 6"300 RFWN SA105 SCH. 80 AVAIL. B&D WELD SHELL

*OUTLET 1 - 6"300 RFWN SA105 SCH. 80 AVAIL. D WELD HEAD
PRESSURE 1 - 1/4"" COUP SA105 6000# AVAIL D WELD SHELL
TEMPERATURE 2 - 3/4" COUP SA105 6000# AVAIL D WELD NOZZLES
DRAIN 1 - 1" COUP SA105 3000# AVAIL D WELD SHELL
BYPASS 1 - 3"300 RFWN SA105 SCH. 40 AVAIL. B&D WELD NOZZLE
11. Supports: Skirt NO Lugs NO Lege N/A Other FLANGES Attached NOZZLES,WELD.
(yes or no) (No.) (No.) (Describe) (Where and how)
12. Remarks: Manufacturers Partial Data Reports properly identified and signed by Commissioned Inspectors have been fumished for the following items
of the report: NONE
(Name of part, ítem number, Mfgr's, name and identifying stamp)
RELIEF VALVE IN PIPING. IMPACT TEST EXEMPT UG20F. *NOZZLE MATERIAL SA1068.
NOZZLE ATTACHMENT WELDS ARE CATEGORY TYPE.
DISCHARGE HEADER , NATURAL GAS . NON-CORROSIVE SERVICE . 9797-12B

We certify that the statements made in this report are correct and that all details of design, material, construction, and workmanship of this vesse
conform to the ASME Code for Pressure Vessels, Section VIII, 1. "U" Certificate of authorization No. 5453
expires 0817 X4WiC4‘ ,..?e19/
Date: 05-17-00 Co. Name: ^00PER ENERGY SERVICES Signed:
(Manufacturer) sentatív
Vessel constructed by COOPER ENERGY SERVICES at OKLAHOMA CITY . I, the undersigned,
holding a valid Commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of OKLAHOMA and
employed by FACTORY MUTUALINSURANCE CO. JOHNSTON.RI have inspected the component described in this Manufacturers Data Report on
05-17-00 A/Vi _ , and state that, to the best of my knowledge and belief, the Manufacturer has constructed this pressure vessel in
accordance with ASME Code, Section VIII, Division 1. By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or
implied, conceming the pressure vessel described in this Manufacturers Data Report. Furthermore, neither the Inspector nor his employer shall be fiable
roperty
in any manner for any personal injury or.pliiiko •amage z
zewsw, ora of~ arising from or connected with this inspection.
Date „7pii,),..2y, „1:500 Sign Commissions A/E; /.2//,9i9 C11¿ gra
(Authorized Inspector) Nen Board (Incl. endorsements, State, Prov. and No.)
Catalog Section 2
Bulletin 2-8 11-81
~Ir
■
•■■=.1,
~sun Ensineer
rntemationai
OMellif
SERIES 7100 "FLO-LIFTZ PISTON CHECK VALVE
1.50" THRU 8" SIZE

1
ANSI RAT1NG
NON-SLAM 150 THRU 2500 FLANGE
NORRISEAL PISTON CHECK VALVES
Series 7100
FEATURES:
Non-Siam Closíng
No Special Tool Required to Changa Seat
Low Pressure Drop
High Cv Values
Smooth Opening
Special Trims for Abrasive and Corrosive Service
Lifting Devise for Piston Removal and Inspection
Positively Prevents Backflow
Teflon Self Lubricating Piston Seal
Two-Piece Guide/Cage
Low Maintenance Costs
APPLICATIONS:
Air or Gas Compressor Service
Gas or Liquid Pipe Lines
Off-Shore Platform Flow Unes
Oil & Gas Production Leases
Pulsating Flows
Safety Systems
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INTRODUCTION:
The NORRISEAL Series 7100 PiSton Check Valve* is designed for the positive prevention of backflow in
ges, air or liquid systems.
NORRISEAL'S "expertise" in designing of Piston + Balanced Control Valves has introduced new con-
cepts to the Piston Check Valve industry.
• Received the Special Meritorious Award for engineering innovation at the 1981 Offshore Technology
Conference in Houston, Texas.
+Received the Special Meritorious Award for engineering innovation at the 1971 International Petro-
leum Exposition in Tulsa, Oklahoma. The award was presentad for the design of the Series 2700 Con-
trol Valve.
OPERATION:
Normal —Flow is directed under the valve piston and lifts it upward. When flow is stopped, the piston de-
scends, closing the valve to prevent flow reversa'.
Stabilized/Non-Siam Piston — Pulsating flow through the valva, if unrestricted, would cause the pistan
to follow the rapidly cycling line pressure, resuiting in vibration, chattering, and possibly slamming of the
pistan. The "Ball Check" and "Orifice Plug" built into the piston are to prevent this from happening. (Fig. 1)
As the piston rises, the pressure in the teflon sealed cavity aboye the pistan increases, forcing open the "Ball
Check". This reduces the cavity pressure and alioWs the pistan to rise smoothly. As line pressure and flow de-
crease, the pistan moves downward. The "Ball Check" clases, and descent of the pistan is restricted by fluid
flowing through the "Orifice Plug". This equalizes the pressure in the cavity aboye and below the pistan and
gives stability to the valve.
e
BALL CHECK ORIFICE PLUG
FIGURE 1
SPECIAL FEATURES:
Teflon Piston Seal Ring — Norriseal's use of a teflon spring energized pistor. ;aal ring adds a new di-
mension to a piston check valve. By use of a full círcle ring, leakage between pisten and guide/cage is zero.
Teflon, being a low friction, self-lubricating material, allows the piston to move freely and quietly with-
out seizing to the sea,.
Guide/Cage — This feature by Norriseai provides positive piston and seat alignment which helps pre-
vent piston vibration and assures stability for proper flow control.
Valva Spring — Furnished as a standard on all valves. This gives an added safety feature for chut-off in MI
pressure ranges. Vaive can operate effectively with spring removed for some applications (see installa-
tion section).
Seat — Non-Screwed in type. Held in position by two-piece guide/cage. No special tools required for re-
moval. Can be easily removed by hand.
Optional Trim — For applications where a positive seal with a "zero" leakage is required, composition
seating material is available. This style piston has the feature of a metal back-up for fire protection or
wash-out of the composítion trim. (Fig. 3)
Carbide trim sets are available for applications where aE -lsion res:stant material is rsluired. (Fig. 3)
NACE — Trim available that meets MR-01-75 recomm ded practica. (See Materials of Constructir.i).
Easy Maintenance — Norriseal's valve piston comes with a' built-in lifting device. No special fittings or
tools required to remove piston from valve body.
ITEM NO. DESCRIPTION
1 SEAT Vaive
2 PISTON Valva Salid
2A BUTT Piston Valva
28 RETAINER Piston Vaive
2C INSERT Piston Vaive
20 SCREW Retainer Piston
2E O-RING Insert
3 CAGE Piston Valva
4 GUIDE Piston Vaive
5 SPRING Valva
6 PLUG Orífice
7 SEAT Ball Check
8 CAGE Balt Check
9 SPRING Ball Check
10 BONNET
11 GASKET Bonnet
12 GASKET Guide
13 GASKET Seat
14 STUD Bonnet W/Nut
15 SCREW Liftinq
16 NUT 1-lex Reg
17 SEAL Pistan Gude
18 BALL Check
19 PLUG Pio*
20 BODY
FIGURE 3
Note: Figure 3 shows piston with carbide or composition insert material.
APPLICATION:
Comprensible Fluida — Valves come with Ball-Check and Orifice Plug in piston.
Non-Compressible Fluida — Valves furnished same as for compressible fluids; however, some applica-
tion where heavy, viscous liquids are present the Ball-Check should be removed, so piston can stabilize
quicker.
1NSTALLATION:
Valves 4" and smaller may be installed in a vertical position. The valve spring should always be installed.
Valves installed in a horizontal piano can be used without the valve spring.
6" and 8" valores should never be installed in a vertical plane. Weight of piston would keep it from closing.
Always install in horizontal line.
MATERIALS OF CONSTRUCTION
' ITEM STANDARD NACE MR-01-75
BODY CAST STEEL A216 WCB CAST STEEL A216 WCB
VALVE PISTON 17-4PH SST 316 SST
VALVE SEAT 17-4PH SST 17-4PH OR 316 SST
PISTON INSERT GLASS FILLED TEFLON GLASS FILLED TEFLON
(OPTIONAL) OR CARBIDE OR CARBIDE
INSERT RETAINER 17-4PH OR 316 SST 316 SST
1.5" 304 SST 304 SST
CAGE 2", 3", 4" 17-4PH SST 17-4PH SST
6" & 8" 316 SST 316 SST
PISTON GUIDE 1018 NICKEL PLATED 1018 NICKEL PLATED
PISTON SEAL TEFLON/304 SST TEFLON/ELGILOY
VALVE BONNET CARBON STEEL ASTM A36 CARBON STEEL ASTM A36
SEAT. 316 SST 316 SST
BALL CAGE 316 SST 316 SST
CHECK BALL 302 SST 302 SST ANNEALED
SPRING INCONEL 600 INCONEL 600
VALVE SPRING 316 SST . INCONEL 600
BONNET STUDS ASTM A193 GR. B7 ASTM A193 GR. 87
HEX NUTS ASTM A194 GR. 2H ASTM A194 GR. 2H
SPIRAL WOUND 304 SST/ASBESTOS INCONEL 600/ASBESTOS
GASKETS
ORIFICE PLUG 316 SST 316 SST
PISTON LIFTING 302 SST 302 SST
ATTACHMENT
NAMEPLATE 304 SST 304 SST
MATERIAL TEMPERATURE LIMITS: -20° + 400° F.
AVAILABLE BODY CONSTRUCTIONS

BODY BUTT SOCKET ANSI FLANGED R.F. & R.J.
SIZE NPT WELD WELD 150 300 600 900 1500 2500
1.50" ' * * *
2.00" * " * *
3,00" *
4,00" * * * . *
* *
6.00" * * * • e *
8.00" * • •
•
•
PRESSURE DROP VS. FLOW FOR NORP'SEAL

SERIES 7100 PISTON CHECK VAL`, S
I 4
100
90
80
70
60 I.
60
40
=30
ND
a.
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LLI 20 ;4
CC 44 ....1
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CC Csh N -1
ci. 10 mo
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• 0 0 0 0 0 o 5 5 5 5 5 58
05 I, ID tO O O
o o o o o o o o o
1 ▪ gr r•-• CD O
1
WATER FLOW (GPM) AT 60°F

NOTE: Dotted portion of curves indicates flow with valve spring removed.
The following formulas may be

FLOW (WATER — S.G. = 1.0) used to determine the actual flow
VS. coefficient (Cv) required by a given
PRESSURE DROP (PSI)
condition of flow. GLOSSARY OF TERMS
FOR LIQUIDS OTHER [ liquids — GPM
THAN WATER MULTIPLY Q = Flow Gas — SCFH
BY 1/ \/S.G.
1. Liquid Cv = Flow Coefficient
FOR BARREIS PER DO
MULTIPLY GPM BY 34.3 ,_-_- I niet Pressure (PSIA)
Cv = QN áP
P2 = Outt et Pressure (PSIA)
FLOW COEFFICIENTS ¡,P IP =PI - P2, Pressure Drop
(Cv) FOR FULLY OPEN VALVES Q = CvN G [Critical flow (gas) use V2
for PI if P2 is less than
Valve Size Cv '/2
II. Gas
1.50 34 T =_Absolute Temperature
GT
Cv (°F 460)
2.00 70 963\ ' (IP) (Pi P2 )
G = Specific Gravity
3.00 128 (.1P) (P, P2) Liquid (water = 1.0) or Gas
Q -= 963 Cv GT
4.00 198 N (Air @ 14.7 psia & 60°F.
= 1.0)
6.00 440
8.00 880
FLOW RATES OF NATURAL GAS FOR VALVE NOTE: With vaive spring instailed in 1.50,
S1ZES AND PRESSURE DROPS SHOWN 2.00 and 3.00 valvas, minimum pressure drop
TABULATED NOS. ARE THOUSANDS OF STD. CUBIC Fr. PER HOUR is 3.0, 3.0, and 2.5 respectively. Therefore,
flow ratee shown for these sizes at oP of 2.0
FLOW RATES ARE AT 70°F PSI are valid only if valva spring is omitted.
SPECIFIC GRAVITY = .65
PRESSURE
INLET ep 1.50 2.00 3.00 4.00 6.00 8.00
PSIG PSI
•
50 2 24.0 40.7 105.4 87.8 234.2 550.5
3 14.6 29.2 75.8 163.3 393.7 875.0
5 37.6 75.3 144.7 245.9 572.9 1157.4
10 61.1 127.6 226.8 351.5 793.7 1587.4
100 2 32.1 54.5 140.8 117.4 313.0 735.4
3 19.5 39.0 101.5 218.6 527.0 1171.0
5 50.5 99.4 194.3 330.3 769.4 1554.4
10 82.7 172.9 307.4 476.5 1075.9 2151.8
200 2 44.0 74.6 193.1 160.9 429.0 1008.3
3 26.7 53.6 139.3 300.0 723.2 1607.1
5 69.3 ' 135.3 267.2 454.3 1058.2 2137.7
10 114.3 239.1 425.0 658.8 1487.6 2975.1
300 2 53.3 90.4 233.9 194.9 519.8 1221.6
3 32.4 64.9 168.8 363.6 876.5 1947.8
5 84.1 163.4 324.1 551.0 1283.5 2592.9
10 138.9 290.5 516.5 800.6 1807.8 3615.6
. 500 2 68.2 115.7 299.3 249.5 665.2 1563.2 '
3 41.5 83.1 216.1 465.4 1122.0 2493.3
5 107.7 208.6 415.1 705.8 1644.0 3321.2
10 178.1 372.7 662.6 1027.1 2319.2 4638.3
600 2 74.6 126.4 327.2 272.7 727.1 1708.6
3 45.3 90.8 236.2 508.7 1226.5 2725.5
5 117.7 227.9 453.9 771.6 1797.3 3631.0
10 194.8 407.6 724.7 1123.3 2536.5 5073.0
2 rt
700 80.4 . 136.3 352.8 294.0 784.1 1842.6
3 48.9 98.0 254.7 548.7 1322.7 2939.3
5 127.0 254.6 489.5 832.2 1938.6 3916.3
10 210.2 439.8 781.9 1211.9 2736.6 5473.2
800 2 85.9 145.6 376.7 314.0 837.2 1967.5
3 52.2 104.6 272.0 585.9 1412.4 3138.6
5 135.6 271.8 522.8 888.7 2070.8 4182.2
10 224.5 469.8 835.2 1294.5 2923.0 5848.1
900 2 91.0 154.3 399.2 332.7 887.2 2084.9
3 55.3 110.9 288.2 620.9 1496.7 3326.0
5 143.7 288.1 554.0 941.8 2193.9 4432.2
10 238.0 497.9 885.2 1372.1 3098.3 6196.6
1000 2 95.8 162.5 420.5 350.4 934.5 2196.0
3 58.3 116.8 303.6 654.0 1576.5 3503.4
5 151.4 303.5 583.6 992.1 2311.1 4668.8
10 250.7 524.6 932.6 1445.5 3264.2 6528.3
1200 2 104.9 177.8 460.1 383.4 1022.5 2402.9
3 63.7 127.8 332.2 715.6 1725.1 3833.6
5 165.7 332.1 638.7 1085.7 2529.1 5109.3
10 274.4 574.2 1020.8 1582.2 3572.8 7145.7
1300 2 109.1 185.0 478.7 398.9 1063.8 2500.0
3 66.3 132.9 345.7 744.5 1794.8 3988.4
5 172.4 345.5 664.5 1129.6 2631.4 5315.9
10 285.5 597.5 1062.2 16484 3717.8 7435.2
1400 2 113.2 191.9 496.6 413.8 1103.5 2593.3
3 68.8 137.9 358.6 772.3 1861.9 4137.5
5 178.8 358.5 689.3 1171.9 2729.8 5514.7
10 296,2 619.9 1102.0 1708.0 3856.9 7713.8
1500 2 117.1 198.5 513.8 428.2
3 71.2 142.7 371.1 799.2
5 185.0 370.9 713.3 1212.7
10 306.5 641.5 1140.4 1767.6
1800 2 128.2 217.3 562.5 468.7
3 77.9 156.2 406.2 874.8
5 202.5 406.1 780.9 1327.5
10 335.6 702.3 1248.6 1935.3
2000 2 135.0 229.0 592.7 493.9
3 82.1 164.6 428.0 921.9
5 213.4 427.9 822.9 1398.9
10 353.7 740.1 1315.7 2039.4
HOW TO ORDER
1. Determine required body size.
2. Use Model Number Code as illustrated to select proper valve type to suit operating conditions.
BODY RATING BODY STYLE
CODE ANSI Code Flow Pattern

Globe SEALS (SPIRALWOUND
02 150 G
GASKETS)
07 300 Á
Code Material
09 400
'S 304 SS T /Asbestos
14 600
21 900 N Inconel / Asbestos
36 1500
60 2500
BODY CONNEC7 .3141 TRIM MATERIAL
TYPE ÍCODE CODE PISTON SEAT
Screwed (Female) NPT S 'A 17-4PH 17-4P1-t

316 17.4PH
Flanged Raised Face RF
C 316 316
Flanged Ring Type Joint RJ
Beveled Buttweld 8
Socketweld FLUID TYPE
36RGS-AEA "A GAS OR AIR

LIQUID
8
SERVICE CODE
STANDARD ■
(GENERAL SERV.) PISTON SEAL MATERIAL
N NACE SPEC. la. E I TEFLON/ELGILOY

MR-01-75 'STANDARD
VALVE SPRING MATI.

BODY FACE TO FACE DIMENSIONS linches) "F"
•R 316 SST
BODY END CONNECTION 1.50 2.00 3.00 4.00 6.00 8.00
INCONEL
SIZE (Inches)
o
L NO SPRING
NPT 8-1/4" 11-1/4"
BUTTWELD 7-3/4" 11-1/4" 9-5/8" 10- 7/8" 15-1/4"
SOCKETWELD 8-1/4" 11-1/4"
150 8-3/4" 10" 11-3/4 13-7/8" 17-3/4" 21-3/8"
300 9-1/4" 10-1/2" 12-1/2" 14-1/2" 18 - 5/8" 22 - 3/8"

ANSI
FLANGED 400/600 11 - 1/4" 11-1/4" 13-1/4" 15-1/2" 20" 24"
BODY HEIGHT RAISED
900 12" 14-3/4" 15-1/2" 17" 24" 29"
FACE
VALVE SIZE D E 1500 12" 14-3/4" 18-1/8" 20-7/8' 27-3/4" 32-3/4'-
(Inches) (Inches)
2500 15-1/8" 16-7/8" 22-3/4" 26-1/2" 36" 40-1/4"
1. 50" 9" 3-9/16"
150 9-1/4" 10 - 1/2" 12-1/4" 14-3/8" 18-1/4" 21-7/8"
2" 12 - 5/16" 4-1/2" ANSI 9-3/4" 11-1/8" 13-1/8" 15-1/8" 19-1/4- 23"
300
3" 12-7/8" 4-7/8" FLANGED 20-1/8" 24-1/8"
400/600 11-1/4" 11-3/8" 13-3/8" 15-5/8'
RING TYPE
4" 15" 6 - 1/8" JOINT 900 12" 14-7/8" 15-5/8" 17-1/8" 24-1.'8" 29-1/8"
6" 17-3/4" 7-1/2" 1500 12" 14-7/8" 18 - 1/4- 21" 28" 33-1/8"
8". 23-3/4" 9" 2500 15-1/4" 17" 23" 26-7/8" 36-1/2" 40-7/8"
CORPORATION / NORRIS DIVISION

AIR COOLED EXCHANGERS, IK C. T7 Y7
P.O. BOX 577 • BROKEN ARROW, OKLAHOMA 74013
(918) 251 7477
Specification Sheet
CUSTOMER AJAX PROPOSAL NO. 2567
REF. NO. DATE 02-10-2000
MODEL J6C ACE S/N 00051 PAGE 1 OF 1
PERFORMANCE OF ONE UNIT
SERVICE TV! AC
FLOW 190 GPM 9.70MMSCFD
FLUID 50%GLY .7155
TEMPERATURE IN, °F 165.0 222.0
TEMPERATURE OUT, °F 150.0 125.0
INLET PRESSURE, PSIA 315.0
PRESSURE DROP, PSI 4.0 4.0
DUTY, Bill/HOUR 1254000 1214991
CORRECTED MTO 33.1 43.8
BABE TUBE BATE 161.7 81.1
FOULING 0.0005 0.002
BARE TUBE SURFACE, SO. FT. 235 342
TOTAL SURFACE, SI FT. 3729 5441
CONSTRUCTION
NO. SECTIONS 1 1
NO. TUBES/SECT1ON 122 178
LENGTH 12 12
NO. ROWS 4 4
NO. PASSES 2 2
COUNTERFLOW
TUBE OIL AND BWG 5/8X16BWG 5/ 8X16BWG
TUBE MATERIAL SA214 STEEL SA214 STEEL
DESIGN PRESSURE, PSI 150 645
DESIGN TEMPERATURE, °F 350 350
NOZZLES 3-150RF 6-300RF
HEADERS CARBON STEEL BOX TYPE WITH REMOVABLE PLUGS
ASME CODE STAMP YES
HPF HPF
GRVD TUBE SHEET
CORROSION ALLOWANCE
FILAS ALUMINUM, ANGLE BASE, MECHANICALLY BONDED
PLUGS, TYPE TAPER TAPER
PLUGS, MATERIAL STEEL STEEL
TURBULATORS
ACCELERATORS
AIR DATA
INLET AIR, °F 10 5 ELEVATION, FT. 852
OUTLET AIR, °F 13 2 TOTAL SCFM 83900
MECHANICAL EQUIPMENT
NO. FANS 1 HP/FAN 26.6 RPM 557 DIA. 96 NO. BLADES 6 MATERIAL ALUM MAKE AFRO O R EQUAL
DRIVE
DRAFT TYPE INDUCED OVERALL WIDTH LENGTH HEIGHT

EST. SHIPPING WEIGHT
ACCESSORIES
Farm U, I0/95,11400a
Grease Lubrication Schedule CT? 7? 7
Link-Belt Ball Bearing Units - Series U300
Lubrication Guidelines for Horizontal Shaft, Grease Lubricated Fan, Blower or Other
High Speed Rotating Equipment
Relubrication Intenta! 6 months 4 months 2 months 1 month

Shaft size range Amount of grease Operating speed (RPM)
MM IN3 CM' Up to Up to Up to Up to
Inches
20 .15 2.5 4,785 7,520 10,940 14,360
3/4
'A -15/16 -1 25 .21 3.4 4,085 6,420 9,340 12,260
11/8-13/16 30 .3 4.9 3,620 5,610 8,145 10,860
35 .44 7.2 3,285 5,095 7,395 9,860
11/4-13/8-17/16
1'/2 40 .59 9.7 3,080 4,930 7,190 9,450
15/8 -1B/16 -13/4 45 .81 13.3 2,640 4,225 6,160 8,100
115/16 50 1.03 16.9 2,310 3,850 5,580 7,315
2 - 2'4 - 23/16 55 1.36 22.3 2,045 3,410 4,945 6,480
21/4-2'/16 60 1.66 27.2 1,830 2,990 4,320 5,815
211/16.23/4 70 2.47 40.5 1,660 2,580 3,865 5,155
215/16 75 2.97 48.7 1,550 2,410 3,620 4,825
3 - 33/16 80 3.58 58.7 1,370 2,225 3,420 4,450
90 4.84 79.3 1,350 2,025 3,040 4,050
37/16 - 31/2
315/16 100 6.54 107.2 1,200 1,885 2,740 3,600
Lubricate with a premium quality NLGI 2 or 3 multi-purpose ball bearing grease having corrosion
inhibitors, anti-oxidant additives and mechanical stability for high speed operation. The grease
should also have a minimum base oil viscosity of 500 SUS at 100° F and be suitable to operate
continuously at 225° F. Do not use a heavy, long fibered grease.
Some suggested greases are:
Mobil Mobilith AW2 Gulfcrown No. 2 or 3
Shell Alvania #2 or #3 Texaco 1939 Premium RB
These units are prelubricated with a multi-purpose Lithium soap grease. When relubricating with
greases of different types (especially synthetic soaps or oils) complete flushing is
recommended.
The presence of dirt, moisture or chemical fumes around the bearings requires more frequent
lubrication. Ambient temperatures below 20° F or aboye 200° F will require special lubricants.
Consult the machinery manufacturer for recommendations.
When vibration exceeds .1 in./sec., frequent lubrication is required and a need for equipment
rebalancing is indicated.
Fill bearings with lubricant prior to extended shutdown or storage. Rotate the shaft several
revolutions each month during idle periods.
These guidelines are for applications approved by Link-Belt Bearing Operation, lndianapolis,
Indiana 46206.
Rexnord
1111111 1 111 2/98 3M CC Printed in U.S.A.
Bulletin No. 3023 © Copyright Rexnord Corp. 1998
AIR COOLED EXCHANGERS, INC.
PHONE 918 251-7477
FAX 918 251-7482
P.O. BOX 577
BROKEN ARROW, OK 74013
OPERATING AND MAINTENANCE INSTRUCTIONS FOR ACE COOLERS
IMPORTANT
Before start up, check set screws and bolts in the fan assembly and set screws in locking
collars of all bearings and sheaves. These items should be checked again several days alter
start up.
FAN & DRIVE
Although the fan and drive are inspected before shipment, clearance between the fan
blades and the fan ring and guard, and alignment of the fan shaft should be checked to
assure that rough handling during shipment has not loosened bearing mounting bolts or
caused misalignment.
V-belt drives should be adjusted until tight enough to prevent excessive belt slippage. The
belt is generally tight enough when it can be twisted one-quarter of a turn with the thumb
and fore-finger.
LUBRICATION
Bearings should be greased in accordance with normal maintenance practice. Over-

lubrication is the most common cause of bearing failure. In general, about one cubic inch
of grease in each bearing every 2 to 3 months is adequate. The operating temperature of
the bearing may indicate how much lubrication is required.
Normal temperature may range from "cool to warm to touch" up to a point "too hot to
touch for more than a few seconds" depending on bearing size and speed, and
surrounding conditions. Unusually high temperature accompanied by excessive leakage of
grease indicates too much grease. Hlgh temperature with no grease showing at the seals,
particularly if the bearing seems noisy, usually indicates too little grease. Normal
temperature and slight showing of grease at the seals indicates proper lubrication.
PG 2
TUBE CLEANING
Operating conditions sometimes cause an accumulation of dirt on the outside fin surface.
This can be removed by directing compressed air, or a greaseless solvent followed by a
water spray through the fins in a direction opposite the normal air flow. The inside of the
tubes will require periodic inspection and cleaning as necessary. Removal of access plugs
allows visual inspection, and if necessary, the use of mechanical tube cleaners.
PLUG LEAKS
Should tapered plugs develop leaks, additional tíghtening is normally all that is required.
Thread dope may be used if tightening alone is not sufficient. If shoulder type plugs
develop leaks, the gaskets should be replaced. Tapered plugs that are removed for the
tube inspection or cleaning should be replaced in the same hole.
TUBE LEAKS
Tube leaks can be of two types: (1) leaks in the tubewall itself (usually corrosion ) and (2)
leaks in the tube to tubesheet joint. In the first case, it is usually most practical to plug
both ends of the tube with the resulting loss in heat transfer surface. When so many tubes
have been plugged that performance is affected, retubing will be necessary. If leaks
develop in the tube to tubesheet joints, re-rolling of the tube will be required. Care must
be used in selection of the proper tube expander for the size and BWG of the tube being
used. As with all rolled tube joints, over-rolling must be avoided.
GENERAL
If it is ever necessary to contact our plant for service or replacement parts, it is essential
that our serial number or other identifying data be obtained form the metal nameplate
attached to the cooler. This is the only way to positively identify the correct parts that
may be required.
AIR COOLED EXCHANGERS, INC.
PHONE 918 251-7477
FAX 918 251-7482
P.O. BOX 577
BROKEN ARROW, OK 74013
AIR COOLED H-EAT EXCHANGER

SUGGESTED START UP PROCEDURE
Before any stars up procedure is begun, a thorough inspection of the Air Cooled
Exchanger should be made.
1.) Be sure all bolted connections are properly tightened.
2.) After tube bundle and piping hydrotest, remove hydrotest connections.
Be sure tube bundle is properly drained, and if required, dried.
Connect process piping and any auxiliary connections.
3.) Inspect all process connection, as well as, vent drain, temperature and
pressure, or any other auxiliary connections to be sure they are plugged or
connected properly.
4.) Check mechanical equipment before starting process through the tube
bundle(s).
a.) Thoroughly check the plenum and fan drive area to be sure all tools
and construction materials are removed.
b.) Rotate the fan by hand and check fan tip clearance and alignrnent of
belts and sheaves.
c.) Check belt tension.
d.) Check all fan drive bolts to be sure they are properly tightened.
This includes bearing bolts, fan and sheave bushing bolts, set
screws, motor bolts and fan blades attachment bolis.
e.) If air operated auto-variable pitch fans are used, check for proper
pitch with the air off. Fans may go to either minimum or maximum
pitch at air failure. Check specifications for requirements. If fan
pitch is not satisfactory, set pitch per manufacturer's instructions
(see Operation and Maintenance Instructions). If fan pitch is
satisfactory, cycle fan through it's range, using plant air and an air
regulator.
PG 2
f.) If air operated louvers are provided, it is advisable to disconnect the

air motor linkage and cycle the louvers by hand to assure there is no
binding or obstruction of the louvers blades. If binding occurs,
check to be sure louver frames are square. Attaching bolts may
have to be loosened and frames shifted to ease binding. If louvers
operate smoothly, reconnect air motor. Cycle the air motor, using
plant air and an air regulator.
g.) If manually adjusted pitch fans are provided, check fan pitch and re-
pitch per manufacturer's instructions if required.
h.) If manual operated louvers are provided, check for binding of the
blades, as in instruction (f). Operate louvers to be sure there is no
linkage obstruction or binding.
i.) Remove condensate drain plugs, if provided, in electric motors and

other electrical components to drain any condensation that might
have occurred during storage. If space heaters are furnished in
electric motors, louver actuators, controls, etc., activate the space
heaters and allow approximately 24 hours before starting
equipment.
Alter all the applicable steps previously stated are completed, the
mechanical equipment may be cycled.
k.) Be sure all personnel and equipment are away from the fan and fan
drive area. For safety reasons, equipment guards should be
installed. Activate the drive motor and let it reach speed. Check
for vibration and excessive noise. If vibration or excessive noise
occurs, immediately shut motor down, and check for loose
connections or insufficient clearance between moving parts. If the
system is running smoothly, replace any guards removed and move
to the next drive and repeat aboye steps.
5.) Start the process through the tube bundle(s). Open the inlet valves slowly
and let the process "Warm" the bundles slowly. This will allow the
components of the tube bundle to expand at the same rate and lessen the
thermal shock.
Parts List Air Cooled Exchangers, Inc
P.O. Box 577
Broken Arrow, Oklahoma 74013
Phone: 918-251-7477
Fax: 918-251-7482
Customer: Cooper Energy Services
ACE Serial Number(s): 00051
Cooler Mode!: J6C
'tem Qty/Unit Description

Fan Make & Mode! 96"_ Dia. 6 Blades 24 deg. Pltch at 2/3R_ Fan PPM:
1
AEROVENT RIGHT Hand 2 7/16" Bore with STD Keyway Special Note:
Fan Shaft 2 7/16" Dia. 81" Long with 6" Keyway one end & 7" Keyway otherend
'I
leiter Shaft 1 2 3/16" Dia. 20" Long with 5" Keyway one end
Fan Bearing 2 2 7/16" LINK-BELT P339
Idler Bearing 1 2 3/16" DODGE FAN & BLOWER OR EQUAL
Electric Motor HP RPM Volt Phase Cycle
Enclosure Frame Size SlideBase
Motor Sheave O.D. Type Groove Bore

Fan Sheave O.D. Type Groove Bore
V-Belts
FAN, SHAFT, BEARINGS & V-BELTS ARE RECOMMENDED SPARE PARTS.
ALL INQUIRES AND ORDERS MUST BE ACCOMPANIED BY COOLER SERIAL NUMBER.
E-Mail the Paris division of our Engineering Department at mailhub@ace-coolers.com

Visit Us on the World Wide Web at www.ace-coolers.com
1.99
ADNIVERt i
GENERAL
INSTALLATION AND MAINTENANCE
IM-100
2-2047
Lubrication Instructions For Ball Bearing Motora
Grease-lubricated bearings, as furnished, are adequate PROCEDURE FOR RELUBRICATION

for a long period of operation without relubrication. A
1. Stop motor.
good maintenance schedule for regreasing will vary
2. Remove grease relief plugo in bearing housings.
widely depending on motor size, speed and environ-
3. Grease with hand gun until new grease appears at
ment.
relief hole.
4. Run motor for ten (10) minutes before replacing re-
The table Usted below suggests re-lubrication intervalo lief plugo.
for motora on normal, steady running, light duty indoor
loada in relatively clean atmosphere at 40°C. (.105° F.) CAUTION: Do not overlubricate. This is a mejor cause
ambient temperature or leso. Fractional horsepower of bearing and motor failure. Make sure dirt and conta-
motora follow a similar schedule to that shown under minants are not introduced when adding grease.
&ames 143 to 215T.
TYPE OF GREASE
Motors with no provision for lubrication are equipped
with sealed bearings and require no maintenance. Lubricate with or equivalent to the following greases:
Motora mounted in inaccessible locations are provided Chevron BRB-2 Standard Oil of Calif.
with extended grease lineo to facilitate lubrication. SRI-2 - Standard Oil Company
They are equipped with relief fittings to prevent over- Alvania *2 - Shell Oil Company
lubrication. The grease linea are filled with lubricant at For motora lubricated with special greases check lubri-
the factory. caban tag on motor.
FRAME SIZE NOTE:

Tsfile al Molaban FOR MOTORS OVER 1800 RPM
Enclosurt 143 to 215T 254 to 326T 384 to 4497
Use Va of tabled period.
Open - DP B 2 years 18 months 1 yeer FOR HEAVY DUTY
DUSTY LOCATIONS
Enclosed - FC B
1 year 9 months
Use V2 of tabled period.
Open - DP F 18 months
FOR SEVERE DUTY
Enclosed - NV B HIGH VIBRATION, SHOCK
Enclosed - FC F Use 44 of tabled period.
Open - DP H 1 year 9 months 6 months "
Enclosed - Lint VOLUME - REFERENCE TABLE
Free-FC B Shaft Diameter Amount of Grease
(At face of bracket) te Add
Enclosed - NV F W to 1W Ye cu. in. or 0.1 oz.
Enclosed - FC H 1W to 1W Y4cu. in. or 0.2 oz.
Endiosad - Lint 9 months 8 months 3 months
17/0 to 2W cu. in. or 0.6 oz.
Free - FC F 2W to 3W 2 cu. in. or 1.6 oz.
Lubrication Instructions For Fan Ball Bearings
Bearings and grease linea on belt driven fans are lubri- Bearings and grease limes on fans that are ordered for
cated in assembly. When lubrication is required, add high-moisture or aboye-normal temperatures have
grease slowly while shaft is rotating until grease comes been lubricated with a special lubricant, Plastilube *2.
rapidly out of the seal. Lubricate at regular intervalo with Plastilube #2 as
indicated in the special lubrication chart usted on the
For extreme conditions lubricate according to experi- following page. Plastilube #2 is available from Warren
ence. For normal conditions, lubricate the bearings Refining Company, Division Parr Inc., 18400 Syracuse
with or equivalent to: Chevron SRI-2 grease. Avenue, Cleveland, Ohio 44110.
LUBJUCATION SCHEDULE
SPECIAL LUBRICATION
OPERATING SPRED (11.214) •
SHAFT 51213 Higa Temperature and Higa Molture
500 I 1000 1 1500 f 2000 2500 1 3000 1 3500 4000 F4500 15000
iNCHES
RELUERICAMON CYCLE (MONTH51 AIRSIREAM TEMPERATURE HOURS
1/2 thru 1 8 8 8 8 6 8 I 4 4 2 2
1.1/16 6." 1.7/11 6 6 8 6 6 6 I 4 4 2 I 1 To 250•F. 4500
-
1.1/2 dor1-314 8 8 8 4 4 2 I 2 2 1 1
To 350*F. 1500
1.7/1 diru 2.3/14 6 8 4 4 2 ' 2 ! 1 1 1
2.1/4 thrw 2.7/11 8 4 4 2 2 1 1 1 To 500T. 1000
2.1/2 shrtl 3 8 4 4 2 1 1 1 1
3.7/11 dr" 3-1/2 8 4 2 1 1 1 Coamit masuLactiame f
Wet Atmosphere at 1000 to
3-111/11 6," 4 8 4 2 1 1 tramite recoanordadaas. Room Temperature 1500
BEARING MOUNTING PROCEDURE tightened by usin,g the two set acrewe mentioned aboye.
It la important to follow the aasembly and alignment BELT TENSION
procedure when making an installation of replacement
hearings. Lnapect the shaft for wear at the bearing Belt tension is very important to the proper operation of
mounting positiona. Shaft diameter should not be un- a fan and to the service life of a V-belt drive. A new fan
dersized more than comercial ground and poliahed Will be received with ita belta properly adjusted; how-
tolerantes. Exceaaive undersizáng Will result in rapid ever, all V-belta stretch in the first few hours of opera-
wenn don. It will be neceseary to readjuat the belt tension
after eight hours of running. Alter 100 hours the belta
1. Place new bearings on shaft loosely, with locking should again be acijusted. Thereaftet periodic inapec.
collera toward the ende of shaft aa ahown in illustration. tion la recommended so belti may be adjusted or re-
Drop mounting boite in place, esnug them and adjust the placed when neceseary.
position of ahaft with proper spacing at either end.
' 1. To adjust the belta, looeen the motor hold-down holt&
2. Center both shaft ende in bowling, uaing the clear- Tighten the belt, uaing the motor base adjusting acrew
ance in the mounting hales for horizontal adjuatinent until the belt appears to be taut You should be able
and ahima if necessary for -vertical adjuatment. deflect the belt alightly by squeezing the toro aldea bet-
3. Tighten the bearinga to the base plata and check the ween thumb ami (breen:igen aixl the belt ehould snap
politica of the ahaft again. Before tightening the lock- back into poeition when released.
ing collera be sure the ahaft and hearings are in proper 2. Retighten the motor hold-down boite and start the
alignment. The ahaft should elide freely end to and. fan. Ir the belt screechea on start-up, it la too locas and
should be tightened further.
A IRFL.OW 3. Allow the fan to run for awhile, stop the fan, and
THRUST check the temperature of the sheave with your hand. If
the sheave geta too hot to touch, the belt la probably too
light. .
V-belt drives on Aerovent fans are purposely sized to
Toro Clearing drive handle considerably more load than would be necessary
for normal drive design. This is done to prolong the life
4. Tighten the eccentric aun locking collar of the bear- of the drive and provide for rainimum maintenance.
ing at the propeller end. (The locking collar desliga pro- 13elts should be replaced when they have obviously be-
vides a positive lock of the Wide inner ring bearing to the come worn, even though they are stip operating. A
shaft. To tighten, turn the locking collar in the direction badly-worn belt will alzo cause undue orear of the
of shaft rotation to the lock position; then tighten the aheave. Replace belta when they show definite signa of
collar set acrew.) wear, otherwise, the sheavee Will become worn to the
5. Grasp the sheave end of the shaft and pull on it; at place where they aleo must be replaced. Never put new
the same time tap the locking collar of the sheave end belta on a badly-worn sheave. This will reduce the ca-
bearing with a soft mallet in the opposite direction, pacity of the drive and cause excesaive belt wear.
toward the propellen Most Aerovent fans are provided with an adjusting
6. The final step is to tighten the aheave end bearing screw aa a part of the motor base for eaay setting of belt
eccentric cara locking collar. tension. However, aman fans or fans using small hora.-
power motora may have only a alotted base plata. Whe:
For special heavy-duty hearings a spring locking collar you adjust the belt tension by moving a motor on a
is usad. The two knurled cup-point set screws extend slotted base, be sure that you block the motor tightly
through the inner ring of the bearing and lock and squarely before tightening the hold-down boite,
onto the shaft. Tighten the propeller end collar first; keeping the motor sheave in line with the belt. The
then take hold of the aheave end of the ahaft, pull and motor aheave =int be parallel to and in line with the fan
then tighten the locking collar. The locking collar la sheave.
When you make replacement of belts on a muiti-groove ADJUSTING VARIABLE
drive, be sure they are used in a matched set. 1f you are PITCH SILEAVES
not sure the belts are matched, observe them in opera-
tion. The tight side should be perfectly straight, and the Many Aerovent belt driven fans are furnished with
belts should run smoothly and in line. The siack side variable-pitch motor sheaves. Sheaves may be adju.sted
should bow out and aleo be in line. If one of the belts for lower fan speeds without concern of over-loading
extends out considerably farther than another, it is an motora. When adjusting sheaves t43 increase fan speed,
indication that the belts are not matched and should be check motor current to be sure motor is not overloaded.
changed. If there is only a slight difference, the normal Keep motor current within nameplate and service fac-
stretching in the first hours of operation will equstlin3 tor ratin,gs.
the belt lengths and the belta will be well matched. The sheaves usad are the VP type and are easily ad-
justed. They come in various styles, depencling upon the
RE P LA C ING BE LTS size drive and motor shaft, all fitted with hollow head
AND BEARINGS knurled point safety set-screws.
Worn belta may be easily replaced without removing fan The following steps should be taken to adjust the pitch
from the system. diameter.
1. Loosen the motor hold-down bolts and move the 1. Release belt tension and remove belt or belta from
motor toward the fan. (This is done by turning a sheave.
jackscrew which is a part of the motor base on modela 2. Loosen setscrew and remove key holding adjustable
having larger motora.) The belt may be slipped off the half of the groove (keys usad on styles 2, 3, 5, and 6 only).
motor sheave and then easily removed from the sheave With styles 3 and 6 it may be necessary to remove the
on the propeller shaft. sheave from the shaft to remove the key.
2. Check the numbers on the belt and make the re-
placement with a belt having the same length and sec-
tion.
3. Adjust motor outward to tighten the belt (see in-
structions on belt tension), and tighten the motor hold-
down bolts. Be sure that the motor is not cocked at an
angle and that the end face of the motor sheave is
parallel to the end face of the driven sheave. Typo I Type 2 Tv04 3
%Wird $eri Tyo* Fee4~4 Mes komboing Ty44
5. 5 ow HM will11 Rey
Since the new belta have a tendency to stretch, it will be KII7
necessary to readjust the belt tension alter a few hours

of run-in.
Fan bearings may be lubricated from the outside
through grease extension linea; however, if it is necea-
sary to remove the fan hearings for cleaning or replace-
ment, read the detailed instructions for bearing mount-
ing procedure. Bearin,gs are accessible through the ac-
cess door in the fan. If there is no access door, then Typhe 4 Typo;
remove a section of duct from the inlet side or remove P54~4 I. Tyim w11444 bre—Key Ilughiew If.dry
S.S. le Rayypey
the fan entirely from the duct system.
1. Remove the machina screws holding the bearing 3. Screw adjustable half of sheave out for a smaller
cover. (If the fan has a shaft seal, you must remove the pitch diameter (decreased speed), or in for a largar pitch
propeller, lift up the drive end of the bearing cover, and diameter (increased speed). Each one-half tura will
push it forward off the end of the shaft.) change the pitch diameter one-tenth of an inch. Adjust
two-groove sheaves the same amount on each groove.
2. Bearings are held in place with ordinary clase 5 4L or A belta will opereta satásfactorily with the sheave
capscrews and locknuts. Use new capscrews and fully closed to a maximum of ave full turna open. 5L or B
locknuts to make the replacement, particularly if there belta will operate satiafactorily with the sheave one full
show signa of corrosion. turn open to a maximum of six full turna open. (Mis will
3. Before reconnecting the grease linee to new bear- insure full contact of the sheave in the groove.)
ings, put a grease gun on the outside fittings and pump 4. Replace the key and tighten setscrew to lock sheave
grease through the linee, making sure that all of the old half in position.
grease is purgad out and grease is up to the end of the
line where it conecta into the bearing. Be sure that you 5. Replace the belts and tighten to proper tension. If
use proper grease - see BEARING LUBRICATION. extreme amount of adjustment has been made, it may
be necessary to replace belts with another length.
The belts, sheaves, bearings, and shaftings used in all
Aerovent Tubeaxial Fans are of standard dimension NOTE: Heavy-duty drives requiring three-groove
and manufacture. New parta are available from the sheaves, motor sheaves larger than 7' pitch diameter, or
factory or from the local distributor of Browning drives belts largar than B section require MVP sheaves and
and Link-Belt hearings. are available only on special orden
TYPICAL MOTOR CURRENT Theme Plum 5Ing 4 Nese
AND STARTER SIZE 230 V 4450 V 575 V 115 V 220 V
Amperes shown are nominal and were used for sizing of X 0 s 3

the starters only. There values are not to be used for ■ 1 a
1 o .3
1 o
3 d _
I o
HP 4 < < te
sizing heaters or other overload protection. Conault the 00 2.9 00
motor nameplate for the correct motor current and refer 1/4 00 00 00 5.8
1/3 1.7 00 .9 00 00 7.2 00 3.6 00
this to the heater size chart for the particular starters 1/2 2.0 00 LO 00 .8. 00 9.8 0 4.9 on
used. 3/4 2.8 00 1.4 00 1.1 00 13.6 0 6.9 00
1 3.5 00 1.8 00 1.4 00 10.0 0 8.0 00
NOTE: When sizing overload heaters, conditiona under 1 1/2 5.0 00 2.5 00 2.0 00 20.0 1 10.0 0
which the starters will opereta twist be considered. En- 2 6.5 0 3.3 00 2.6 00 24.0 1 12.0 0
closed starters should have heaters one size larger than 3 9.0 0 4.5 0 4.0 0 34.0 1 17.0 1
15.0 1 7.5 0 6.0 0 21.0 1
open starters. Where enclosures are subjected to exter- 5
11.0 1 9.0 1 40.0 2
7 1/2 22.0 1
nal heat, such as radiant haat from the sun or heat 10 27.0 2 14.0 1 11.0 1. 50.0 3
accumulation under a roof, it may be necessary to in- 15 , 40.0 2 20.0 2 16.0 2
crease the size even more. Experience with the operat- 20 152.0 3 26.0 2 2L O 2
ing conditions and measurement of the actual line 25 164.0 3 32.0 2 26.0 2
current Will aid in proper sizing of heaters.
INSTALLAIION INSTRUCTIONS FOR PROPELLERS EQUIPPED

WITH BROWNING MALLEABLE IRON SPLIT TAPER BUSHINGS
Aerovent propellers are furnished with split tapar bush-
ings for mounting the propeller to the shaft. When prop-
erly assembled, the bushings grip the hub with a posit-
iva clamping action.
A. Bushing barrel and bora of propeller are tapered -
this usuree concentric mounting and a true running
propeller.
B. Capecrews, when tightened, lock bilehing in propel-
lar. Use plated capecrews threaded fuJi length.
_
mo.
HOIli DIA~ umeTH TIMIQUE
FT. all.
H 1/4-20 1W 71/1
13
force propeller and bushing onto shaft. If it does not go
P-1 5 /111 •18 11/2"
13/41 13
on easily, check shaft, bushing, and key size*.
P-2 sil ii - 18
0-2 34-18 2W 24 Tighten capecrews progressively with wrench. Do this
R-2 34-18 3" 24 evenly as in mounting an automobile wheel. Take a part
turn on each capecrew succeesively until all are tight.
C. Bushing te split so that when the locking capecrews These capscrews force the tapar bushing into the hub
force bushing into tapered bone, the bushing gripe the which in turn compressed the bushing arito the shaft.
shaft with a positiva clamping frt - this will withstand This malees a positiva clamping $t. The torque must not
vibration and ptiniahing loada without being loasened. exceed that shown in tabla at left.
D. Propeller and buahing assembly is keyed to ahaft WARNING: Do not attempt to pull buahings flange
and held in place by compression - this gives added flash with hub end- there ahould be 17V to 1/4" clearance
driving strength. when tightened.
E. Propeller is easily removed from shaft by inserting REMOVING PROPELLER ASSEMBLY
and tightening two of the capecrews into the tapped
boles in the bushing flange - this forces the bushing FROM SHAFT
looee from the propeller and raleases the compression so
that the entice assembly will elide from the shaft. 1. Remove all three capecrews from propeller and hub
assembly.
Put bushing loosely Luto propeller. Do not presa or drive.
Start capscrews by hand, turning theta just enough to 2. Start capecrews into the threaded boles in the bush-
engage threads in tapped boles on propeller. Do not use ing Unge
a wrench at this time. The bu,hing should be loare 3. Tighten each bolt part of a turn successively to foro
enough in the propeller to move slightly. the propeller off the buahing.
Be sure shaft and keyway are clean and smooth. Check 4. Pull the bushing off the shaft. If the assembly has
key size with both shaft and bushing keyways. Slide been in place some time it may be necessary to use a
wheel puller to remove the buahing. Never use a wheel
propeller and bushing aseembly onto ahaf, making al- puller on the propeller.
lowance for end play of shaft to prevent rubbing. Do not
114.100 (2.20.rry
>41110YENT INC.. 1 AEIROVINT DRIVE. MOUA. 0,110
TD-1272
PAGE 1 OF 7
REV. 6-3-86
COOLER KELT DRIVE RECOMMENDATIONS
This TO is being issued to establish some general parameters for installing

cooler drive belts, maintenance on them and specific tension instructions.
The primary premature failure of the cooler drive bearings is the

overtightening of the belts.
Some general rules for tensioning belts are as follows:
I. Apply tension to the belts by increasing the idler tension
until belts are snug and have a live, springly action when struck
with the hand.
2. Operate the drive for a few minutes to seat the belts in the
sheave grooves. Look at the drive in its highest load condition
which will probably be when the unit is in a very unloaded
condition with eratic firing of the power cylinders. A slight
bowing en the slack side of the drive indicates adequate tension.
Excessive bowing or slippage indicates insufficent tension. If the
slack side remains taut (straight) during the peak load, the drive is
too tight.
3. Check the tension un a new drive severa] times, during first 24

hours of operation. (run in period) It is recommended by belt
Manufacturers to tension new drives with a 1/3 greater defiection
force than the maximum recommended force and check tension
trequentry during first Z4 hours ot operation.
4. For more of a scientific approach in tensioning of belts see

TD-1272 page "4", describing use of a V-belt tension meter which
Ajax highly recommends for single strand individual belts Gates P/N
12998-F tension meter which sells for around $5.00.
Note: For single strand "V" belts each individual belt is measured
with the tension meter. See table I for standard white hat drive
tension force.
For Drives other than standard driven see table II for tension force.
5. For power band common backed belts the elongation method is

(SEE TABLE III AND IV) recommended. Belt tensioning procedure for
belts after break in period with running time en them.
a. Tape measure the outside circumrerence of the belt in a loose
or no tension position.
b. take this distante in inches and multiply it by the elongation

factor shown in table IV, which will give you a new outside
circumfrence length in inches.
c. Using a fíat flexible narrowtape measure and having it en the

outside of the belt where the idler comes in contact with the belt
and run the tape around the outside of the belt as the tension is
applied. Keep checking the circumference and applying tension
until the correct circumference is achieved.
d. Scribe a line on the idler channel to relocate the postion of

the idler when idler is loosened to remove tape.
e. Reposition the idler to the scribe mark nade in step 4.

TD-1272
PAGE 2 OF 7
REV. 6-3-86
General guide lines for belt drive maintenance.
a. Over tensioning will shorten belt and cooler bearing life.
b. Sheave misalignment will shorten belt life and cause belts to

come off sheave.
c. The idler must be perpendicular to the belts and the cooler must
set level to the unit sheave.
d. Keep oil, Brease and any other foreign material away from belts.
e. When replacing belts always replace the complete set with a set
of matched belts.
f. Worn sheaves can reduce belt life substantially. A gauge which measures
how deep the belt sets in the groove in relation too what it should be is
available. Gates, P/N 13998 belt and groove gauge is available for
checking wear on the sheave groove and belts themselves.
g. Belt turnover or belts coming off sheaves indícate a condition of drive

misalignment, worn sheave, excessive vibration, idler out of
perpendicularity to belts or severe shock loads such as a unit running
very unloaded could cause severe shock load.
TD-1272
PAGE 3 OF 7
REV. 6-3-86
TABLE II
RECOMMENDED DEFLECTION FORCE-NON STANDARD WHITE HAT DRIVES
INDIVIDUAL STRAND BELTS
BELT SMALL SHEAVE SMALL SHEAVE SPEED RATIO RECOMMENDED DEFLECTION

CROSS DIAMETER RPM RANGE RANGE FORCE LBS. PER BELT OR
SECTION CINCHES) BELT STRAND
PITCH DIAMETER MIN. MAX.
3.0 1750 . 2.0 2.7 3.8

3.2 2.9 4.2
A 3.4-3.6 TO TO 3.3 4.8
3.8-4.2 3.8 5.5
4.6-7.0 3600 4.0 4.9 7.1
4.6 1160 2.0 5.1 7.4

5.0-5.2 5.8 8.5
B 5.4-5.6 TO TO 6.2 9.1
6.0-6.8 7.1 10.0
7.4-9.4 1800 4.0 8.1 12.0
7.0 870 2.0 9.1 13.0

7.5 9.7 14.0
C 8.0-8.5 TO TO 11.0 16.0
9.0-10.5 12.0 18.0
11.0-16.0 1800 4.0 14.0 21.0
TD-1272
PAGE 4 of 7
INSTRUCTIONS FOR USING THE V-BELT TENSION

METER
PROCEDURE
1.Measure the span length of the drive.(See Figure 1.)
Set the large"0" ring at 1/64" for each inch of belt scan.
For example, set the large"0" ring at I/4"for a span
length of 16"; uf 1/2" for a span length of 32"; at 1"for
a scan length of 64", etc. (See Tabla 1.)
2. Set the small "O"ring atzero and press clown the Tensiometer
at the center of the belt span (See Figure 1.)
a, On a single belt drive, depress the Tensiometer until
the larga "Ouring is even with the bottom of a straight
edge placed on the outside rims of the two sheaves.
On a multi-ple belt drive, depress the Tensiometer HERE
until the larga "O"ring is even with the top of the next belt.
Measure each belt in the drive, and talle the average
reading of ali belt tensions as explained below.
SMALL
3. Remove the Tensiometer, and observe that the small"0" uou
ring has moved from its original setting at zero to the
RING
number of pounds required to deftect the beit to the
extent notad aboye.
4. Check Chis reading against the values of Pmi n. and Pmax.

(See Table 1.)
Where t = Scan length, inches

C= Center distance, inches
O= Larga sheove diameter, inches
d= Smal I sheave diameter, inches
Note: Deflection height =h=1/64*. per inch of span.
Lij
=
1101
RING
ZACÉP IS END AT M1D-

POI NT OF BELT SPAN
FIGURE 1 V-BELT TENSIOMETER

MEASURING DEFLECTION FORCE
• ▪
-
•
uf) CDCM CD
I n.. CM 1.9 CIN 1i7 ar pl poN m'Y r7 1.1
im• 02 C1 if; mi m4 m4 44 .4 7.1
• CC = C4 N 0.1 N ru rw
2•C SCIC
Id•• CM
Un ~O ..
• • • •
W, 0. 0 CON CD CD C.S el N 02
■■• OW
0. 04
••■••• •••••••■•• •••• .11.411
117 CNa. 0.
• • • • • • • •
qr gr m. tO Su S% op a1 0 gr CD 02 as N ow
ow ou rw
Lf/
61.1
11 a e 2 II N N N
• w11 10 e %0 4:1• 1 4
' s ml ol el
ru ....ow....OW04.. e "••••
mme
".•••
~
••••• e
's..
e
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TD-1272
PAGE 6 OF 7
REY. 6-3-86
TABLE III
COMMON BACKED BELTS
DAYCO SUPER VEE-BANO
(NEW BELT INSTALLATION ONLY)
MIN. NORMAL MAX. NORMAL INITIAL BREAKIN

UNIT BELT TENSION LENGTH TENSION LENGTH TENSION LENGTH
CIRCUMFERENCE CIRCUMFERENCE
DPC...600
DPC-360
J
"J" *
-
C 128'
C-136
1334/16 -
133 1/4 -
133 5/16
141-1/16 141-5/16 141-11/32
DPC-360 "C" C-144 149-3/32 14941/32 149-13/32
DPC-280 "C" C-144 149-3/32 14941/32 149-13/32
DPC-230
OPC-180
"C"
8-105
-
140 29/32
108-13/16
141-1/16
108..29/32
141-5/32
109
OPC-140 B-133 136-7/8 1374/32 137-3/32
DPC415 B-128 131-13/16 131-15/16 132-1/32
OPC-105 8-97 100-11/16 1004.5/16 100-7/8
DPC-80 8-105 108-3/4 108-27/32 108-29/32
OPC-81
DPC-60
8-97
8-97
100-5/8
100...21/32
-
100 3/4
100-25/32
100-13/16
100-27/32
*VERTICAL DISCHARGE COOLER

ALL OTHER UNITS ARE FOR COOLER MOUNTED ON SAME SKID AS UNIT.
(WIDE SKID PACKAGE)
TABLE III
GATES POWER GANO
(NEW BELT INSTALLATION ONLY)
MIN. NORMAL MAX. NORMAL INITIAL BREAK-IN

UNIT BELT TENSION LENGTH TENSION LENGTH TENSION LENGTH
- -
DPC-600
DPC-360
'J
"J"
C-128
C-136
132 7/15
140-15/32
132 21132
140-11/16 --
132 23/32
140 3/4
DPC-360
DPC-280
DPC-230
"C"
"C"
"C" .
C-144
C-144
C-136
148-1/2
148-1/2
140-5/16
--
148 3/4
148 3/4
140-15/32
148-25/32
148-25/32
140-9/16
DPC-180
DPC-140
8-105
8-133
108-5/8
13641/16
108-23/32
136-27/32
--
108 25/32
136 29/32
DPC-115
DPC-105
8-128
8*97
131-19/32
100-1/2
-
131 3/4
100-5/8
131-13/16
-
100 21/32
DPC-80 B-105 108-17/32 108-21/32 108-11/16
DPC-81 B-97 100-13/32 100-9/16 100-5/8
DPC-60 8...97 100-15/32 100-9/16 100-5/8
* VERTICAL DISCHARGE COOLER

ALL OTHER UNITS ARE FOR COOLER MOUNTED ON SAME SKID AS UNIT
o i o
TD -1272
PAGE 7 OF 7
REY. 6-3-86
TABLE IV
COMMON BACKED BELTS
USE TO MEASURE ELONGATION OF BELTS UNDER TENSION
UNIT BELT MIN. NORMAL MAX. NORMAL INITIAL BREAK-IN

ELONGATION ELONGATION FACTOR
FACTOR FACTOR (USE FOR NEW BELTS)
DPC-600 "J" C-I28 1.00339 1.00500 1.00534

DPC-360 "J" C-I36 1.00339 1.00500 1.00534
DPC-360 "C" C-I44 1.00339 1.00500 1.00534
DPC-280 "C" C-144 1.00339 1.00500 1.00534
DPC-230 "C" C-136 1.00214 1.00339 1.00393
OPC-180 B-105 1.00576 1.00659 1.00727
DPC-140 B-133 1.00500 1.00614 1.00659
DPC-115 B-128 1.00458 1.00567 1.00631
DPC-105 8-97 1.00500 1.00614 1.00659
DPC-80 B-105 1.00500 1.00596 1.00646
DPC-81 B-97 1.00413 1.00553 1.00614
DPC-60 B-97 1.00458 1:00576 1.00631
* VERTICAL DISCHARGE COOLER

ALL OTHER UNITS ARE FOR COOLER MOUNTED ON SAME SKID AS UNIT
THE PROPER BELT TENSION IS DETERMINED BY TAPE MEASURING THE OUTSIDE

CIRCUMFERENCE IN INCHES MULTIPLIED BY THE ELONGATION FACTOR WHICH WILL GIVE A
BELT LENGTH IN THE TIGHT POSITION.
"TD-1301
6-27-80
Revised
PROCEDURE FOR GREASING FAN HUBS

(WITH TWO PIPE PLUGS IN HUB)
1. Using a high grade bearing grease per the specifications listed below,
remove both pipe plugs in Fan Hub or seals may be ruptured when
greasing.
2. Instan grease fitting on one of the openings and fill with grease until
grease comes out other open hole.
3. Remove grease fitting and install pipe plug as fitting will probably
throw grease out.
4. Lubricate every 4000-5000 hours of service.
The grease shall be a smooth, well-compounded product, composed of a

high grade soap and refined filtered mineral oil.
CONSISTENCY
ASTM Penetration at 77°F

No. 1 grease 310-340
No. 2 grease 265-295
Ash 2 percent
Moisture 1 percent mínimum
The oil from which the grease is compounded shall conform to the
following specifications:
Flash 340°F Min. Viscosity 200 Saybolt Universal
Fire 380°F Min. Seconds Min. at 100°F
Cold Test (pour) plus 30°F Max.

TD-1350
Rev. 9-18-87
"IDLER PULLEY ALIGNMENT"
As you are aware, proper alignment of idler pulley in all directions is

critical to allow the belts to ride and wear properly. Please assure the
following procedure is used when setting up an off-skid cooler or cooler on
skid.
1. Set cooler according to skid hole centerline

dimensions on general arrangement or foundation
drawing. Make sure holes in bottom skid of unit
are at proper location from edge of skid before
setting cooler.
2. Level cooler shaft by adjusting leveling screws on

cooler skid.
3. Check parallelism of cooler shaft to bottom of

cooler skid.
4. Mount cooler sheave so that belt grooves are

aligned with unit sheave belt grooves. Note:
After aligning the belt grooves, the cooler sheave
should be centered on cooler shaft extending from
the ouside pillow block (bearing assembly.)
S. Check parallelism of cooler sheave to unit sheave.
6. Check parallelism of idler mounting slide on cooler

to unit and cooler sheave.
7. Check idler mounting slide for plumb (i.e.

perpendicular to cooler shaft).
8. Mount idler pulley to slide and check to see if

center of idler pulley is aligned with center of
cooler sheave.
Any discrepencies from this procedure which cannot be corrected without

altering the cooler should be reported to liaison engineer or Corry
Engineering Department.
Gavazzi/1-5-84
(Alternative Form for Single Chamber, Completely Shop-Fabriciated Vessels Only)
1. Manufactured and certified by MR COOLED EXCHANGERS, INC. ONE ACE AVE. BROKEN ARROW, OK. 74013
2. Manufacturad for COOPER ENERGY SERVICES 2101 SE 18TH ST OKLAHOMA CITY, OK. 73129
(Name and adanes of porches«)
3. Location of installation UNKNOWN

(Name and address)
4. Type VERTICAL 00051-2 NA 00051-H NA 2000

Mon, or ven., tanid (Migra sena) No.) (CON) (Drawing No.) (Net*I. Bd. No.) IYear buil()
5. The chemical and physical properties of all parts m eet the requirements of material specifications of the ASME BOILER AND PRESSURE
VESSEL CODE. The design, construction, and workmanship conform to ASME Rutas, Section VIII Division 1 1998
Ver
to
A99 NONE NONE
Addenda (Date) Code Case Nos. Special Service par UG•120101
Tube & Plug
6. shall:
SA-516-70 1" 0" 5-1/2" 5'-8-7/8"
Mall. (Spec. No., Grade) Nom. Thk. Corr. Allow. (in.) Diarn. I.D. (ft. es in.) Length (oyeran) (h. &
7. Seams. SINGLE BEVEL NA NA NA NA NA NA NA

Long. (Weide& Dbl., R.T. (Spot or Fall) EH. (%) H.T. Terne. 1°F) Time (hr) Girth (Welded, DM., R.T. (Spot, Panial, No. of C010304
Sngl., Lep, Buttl Sngt., Lep, Ron) or Fui()
8. Heads: (a) Matl SA-516-70 (b) Matl SA-516-70

1S so. No., Grade) ISpec. No., Grade)
Location (Top, Minirnum Corrosion Crown Knuckle EllIptical Canica) Hernispherical Flat Sida to Pressure
Bottom, Endsl Thicknesa Alio wance Radius Radius Ratio Apex Angla Radius Diameter (Convex or Concave}
(a) TOP/BTM 3/4" 0" NA NA NA NA NA 6" NA

lb) ENDS 3/4" 0" NA NA NA NA NA 6" NA
if removable, bolts usad (describe other fastenings)
(Man., Spec. No., Gr., Size, Na.)
SERVICE: AC
9. MAWP 645 psi at max. temp 350 oF
„..---,... min. design metal teme. -20 °F at 645 psi. Hydro., prree,;--er-e-ererb, test pressure
968 psi
10. Nozzles, inspection and safety valve openings: SAFETY RELIEF VALVE TO BE PROVIDED ELSEWHERE BY OTHERS
Purpose Diem. Nom. Now
No. Type Matl. Loca t ion
(Info(, Outlet, Main) Or Size Thk. Matt. Attached
IN/OUTLET 2 6" PIPE SA-106B XH MATERIAL & WELD UW16.1(a)

2 6" RFWN SA-105 300# MATERIAL & WELD WELDED
1 1" CPLG SA-105 6000# MATERIAL & WELD UW16.1(a)
1 1-1/2" CPLG SA-105 6000# MATERIAL & WELD WELDED
11. Supports: Skirt NO Lugs

2 Lego O Other
NA Attached
TUBESHEET/WELDED
(Ves or no) (No.) (No.) (Where and how)
12. Remarks: Manufacturar's Partial Data Reporto properly identified and signed by Commissioned Inspectors have been furnished for the following items of
the report' CONSTRUCTED IN CONFORMANCE WITH APPENDIX 28, IMPACT EXEMPT PER UG-20(t)(1)(b)
(Name el part, kern (tumbar, M)gr's. nano and identifying stamp)
Tu BEs:(178) SA-214 X 5/8" OD X .060" MW X 12' LONG STRAIGHT TYPE
PLUGS: (356) SA-105 TAPERED

We certify that the statements made in this report are correct and that andetails of design, material, construction, and workmanship of this vessel con-
form to theASME Code for Pressure Vessels, Section VIII, Division 1. "U" Certificate of Authoriza o. 76 expires 4/30 20 02
Date - 3- 00 Co neme MR COOLED EXCHANGERS, INC. Signed
'Manufacturar) fWd esentatr~

Vessel constructed by AIR COOLED EXCHANGERS, INC. at BROKEN ARROW
I the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of
OKLAHOMA and employed by
COMMERCIAL UNION INSURANCE CO. BOSTON, MASS.
have inspected the component described in this Manufacturer's Data Report on 1 1( 20 00 and state that, to the best of
my knowledge and belief, the Manufacturer has constructed this pressure vessel in accordance with ASME Code, Section VIII, Division 1. By signing
thís certificate neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the pressure vessel described in this Manu-
facturer's Data Report. Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage
or a loss of any kind arising from or cor ted with this ins
Date 9 -U -e° Signed —/

Ukuthorized Inspector)
CommissionsA.1-4=-14(1
INr'l r end. endorsements), State, (hov. and No.)
1;2(871 This farm 450011 71 may be obtained from the ASME O rder Dern., 22 Lao Onve, Box 2300, Paoliold, NJ 07007 2300
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TD-1297
MURPHY PANEL TEST PROCEDURE-FIELD
1. With the 379 tattle tales in panel below is the proper fuel
valva hook-up.
A. Connect wire from terminal *4 in fuel valve to terminal
*2 in control panel.
H. Connect a jumper from terminal #1 in fuel valve to terminal
#3 in fuel valve then connect a wire from terminal *3 in
fuel valva and run to terminal #3 in control panel.
C. There normally is a jumper between terminal *8 and terminal
*9 in fuel valva. This must be removed. Other wires that
are connected to terminal *8 and *9 will remain at their
respective terminals.
D. .NOTE: If this jumper is not removed the fuel valva will
not trip when called upon for a shutdown.
E. The ignition will be grounded out directly thru the switch-
gauge.
F. Ground *5 terminal in-fuel valve. This can be done by runn-
ing a jumper between *5 terminal and *10 terminal in fuel
valve M50-78-CD.
G. There may have been a jumper installed at factory between
terminals *2 and 114. If'so, this must be removed for
assurance of tripping the fuel valve without tripping the
master shutdown, which should only be used if no fuel valva
rg—installed.
2. When fuel valva M50-78-CD is not used in system omit fuel valva
connection - steps (1) a thru g - and add jumper between terminal
*2 and *4 in control panel. This will allow the grounding of
the ignition Only for shutdown. This jumper may have been in-
stalled at factory.
CHECK OUT
A. With all safety switches ungrounded we should have the neon
light onindicatingignition on panel with unit running.
B. If unit will not start in most cases there are ene or more
switches not cleared from ground or the M50-78-CD fuel valva•
has not been reset to the open position.
C. If fuel valva is in reset position and neon light in

panel does not come on we can use the adaptor in panel
to determine what sensors are completing circuit te
ground for tribbinc the 379-PH Tattletale by disconry-
ecting the wire at terminal *2 in control panel. With
the ignition system running touch wire back to *2 terminal;
any sensor grounded should trip tattletale. Clear the
sensors from ground. (Reconnect wire permanently to
terminal #2) You should then be ready to complete
check on complete safety shutdown system.
D. Proceed checking system out by momentarily grounding
out each sensor. When sensor is grounded the respective
Tattletale indicator and fuel valve will trip. The
Tattletale should be reset and fuel valve reset before
going on the next sensor.
MURPHY PANEL TEST PROCEDURE-FIELD - PAGE 2
HOW TO CHECK EACH SENSOR
OPL-F Dial contact until made with pointer.

SPL-F Dial contact until made with pointer.
20-T Use jumper wire connected to ground and touch contact
on front of gauge.
25-P Use jumper wire connected to ground and touch contact
on front of gauge.
L-1200 Grasp micro switch Level arm and gently pull down until
micro switch tripa. If micro switch does not trip you
may need to adjust micro so travel of float will then
trip it.
OVERSPEED SW. Trip arm as would happen when engine is in overspeed
condition.
VS-2 Trip switch by tapping on case with block of wood or
hammer handle. If it does not trip it is not set
sensitive enough. Adjust until tripping can be acc-
omplished.
LR-900EX Raise pointer until micro switch transfers then touch
switch wire to the terminal which it will be connected
and let the pointer down until micro switch transfers
tripping Tattletale.
LUBRICATOR OIL LEVEL: Raise float to top of reservoir and touch wire
to connection terminal and lower float to trip
Tattle tale.
50-FLOW SWITCHES: These switches are normally a closed switch which
prevente operating the switch check and can only
be nade by touching the switch wire to terminal
it is connected to and trip the Tattletale.
OPTION
"MASTER SHUTDOWN"
This .s installed in panel to be usad when customer does not
require the use of the M-50-78-CD fuel valva. When checking
system usinq the Master shutdown 221-PH w/72 OHM Coil, use same
procedure as checking panel with fuel valva. Ignition grounding
is accomplished only when Master shutdown trip.
Please note master shutdown will not trip if fuel valve is being
used .t is Only to be usad if there is no fuel valva arailable.
'TEST CIRCUIT'
Thísconsistof (1)15-T timar and (I) 22I-PB 72 OHM Coil.
This circuit is to allow one person to check his safety shut-
down system out without killing engin.. By winding the timar
it disconnects the signal to the fuel valva for tripping and
transfers it to the Tattle tale labeled "Fuel Valva Disconnect'.
You use the same procedure in checking out the system as you
would if fuel valva were in the circuit. The indicator for each
function will trip and fuel valva reset will trip without killing
the engine.
I do suggest that in total checking your system out that once
you have completad the test for circuit continuity using the
Test Timer and "Fuel Valve Reset' Tattletale, return the timar
to zero position and at least one time trip and indicator and
trip fuel valva which will shut the engine down. This will assure
total check of safety system.
MK3-95052B
irytiviirphij Revised 01-98
Catalog Section 50
(00-02-0116)
Digital Fault Annunciator TATTLETALE®

by Murphy SELECTRONIC®
MARK III Series
• Monitors Engine Driven Pumps and
Compressors for Alarm and Shutdown
1117-Bit Binary Code (BCD) Port
• Built-in Power Supply
• 32 Sensors Can Be Displayed
• Approved for Class I, Division 2,
Group D Hazardous Áreas
"I
e g
When installed per Murphy Drawings:
HA14227 and HA14228. Cali Murphy for details.
NRTL/C
Description Basic modeis Sensor Inputs: MARK III accepts 32 sensor

The MARK III Series modeis are solid-state Two MARK III modeis are available: switches, These can be either normally open
or normally closed passive switches.
fault annunciators and shutdown control sys- MARK III-N: for negative ground CD ignition.
tems, designed to protect engines and associated Inputs 1-32: Designated as Class "A"sensors.
MARK III-12/24: for 12 or 24 VDC systems.
equipment. The MARK III modeis can be pow- Inputs 1-9: Can be selected as Class "B"
ered from either a negative ground CD ignition Features sensor lockouts.
or from 12 or 24 VDC (specify). • Built-in power supply. Input 9: Delayed for 20 seconds unless
• Plug-in sensor terminal blocks. selected as Class "B"sensor lockout.
MARK III accepts 32 sensor inputs. Signal inputs
• Alarm and shutdown for up to 32 sensors. Input 30: Can be dedicated for remote lock-
are supplied from normally open and/or normally out input or for remate reset option.
closed sensors. A Liquid Crystal Display annunci-
Sensors 1-9 are used for timed, alarm-
override at start-up. Input 31: Overrides test timer, (typically
ates any fault from the sensor inputs. used for remote stop input).
Sensor 30 is typically used for optional
The built-in test mode allows to test the sensor remote lockout input or remote reset option. Input 32: Overrides test timer dedicated for
circuits without shutting down the equipment. A Sensor 31 is typically used for remote stop. overspeed sensing.
selectable start-run timer (0-9 minutes) can be Sensor 32 is used for overspeed sensing. Outputs (all modeis): FET (Field Effect
used during start-up. • Monitoring and annunciation for ignition volt- Transistor); 0.5 amp @ 250 V maximum.
The remote lockout input option resets the start-run age drop or ignition failure (ignition models). Output Selections:
timer and enables the Class B lockouts. The remote • Easy-to-read liquid crystal display indicates • Ground ignition immediately.
reset option is offered to reset the complete unit. the tripped sensor and allows you to view the • Trip fuel valve, then ground ignition after a
timer countdown during start-up. 2-3 second factory-set delay.
An optional BCD Pon, D-Sub type (7 bit BCD
code), is used to interface with micro-controllers. • 3-second time delay allows the fuel valve to Note: MARK 111-12/24 outputs switch "ON" for nor-
close before grounding the ignition. mal operation; operation can be reversed in field.
Onboard backup battery retains the fault display
• Optional BCD port (7-bit binary code) to Sensor Terminal Block: Four plug-in terminals
after engine shutdown. The annunciator provides with screw type connections and factory
interface with micro-controllers.
for both closing of a fuel valve and grounding of installed jumper for each terminal.
the ignition for shutdown. A time delay of 2-3 • Optional remote lockout input to reset start-run
timer and to enable Class "B" sensor lockouts. Operating Temperature: -40 to 185°F
seconds (approximately) in grounding the igni- (-40 to 85°C).
tion after the fuel valve closes is also included. Specifications Storage ibmperature: -40 to 302°F (-40 to 150°C).
An ignition monitoring and annunciation feature Power Consumption: 700 pa, 100 VDC. Case: Anodized aluminum.
is included to monitor low ignition voltage or Power Inputs (Operating Voltages): Multiplexer Scan Bate: 0.75 seconds.
ignition failure (ignition powered modeis). MARK III-N: 90-250 V, CD ignition, Start-Run/Test Time: Selectable from O thru
Number 41 is displayed when ignition voltage negative ground. 9 minutes (1 minute increments).
drops below 75 VDC (approximately). Number MARK 111-12/24: 12-24 VDC @ 4.7 watts Backup Power (AH modeis): Onboard
40 is displayed in the event of a manual stop. max. including 2 externally operated relays. 6 VDC @ 1300 mAh, DL223A lithium.
Dimensions-AII Models Typical Wiring Diagrams
6-1/2 in.
©
(165 mm) 2-9/16 in. WARNING: Typical wiring diagrams are shown for clarity only.
• • (65 mm)
These diagrams are not intended for use as installation instructions.
6 1/2 in. MARK III-N Model

(165 mm) Customer Wiríng Field connections
1
Fuel ValveColl ignftion
E Engine 90.250 VDC
■ Ground- ---;
• •
clearance for
sensor terminal
.1,2E C(C, l e
+
Q•
block; 3-7/8 in.
(98 mm) o > 4, + CLASS
• < z Lfthium battery
3/16 in. (5 mm) 6 in. (152 mm) t7r •
TIMBA
• DL223A 6 VDC.
dia. 4 places 5-1/2 in.
.1'1140 mm)---"1. Sensor Input
terminal strips O
3 in. ilaego4:10000e00eceee]
5-1/2 in. (76 mm) 16 BCD Port
(140 mm) oecnecoostDetbeeeeee
17
oemomeeomeeesse 111
6 in.
mmr—i O
lorauDemoodurynraseocoGI
(152 mm)
• y
MARK 111-12/24 Model
Customer Wiring Field connections
r
How to Order +12/24 VDC
To order the MARK III specify the following:
Example: MARK III - N - BCD - RL Engine

Ground
Power Source • ROP
N = Negative ground CD ignition O >111" CLASS B
12/24 =12 or 24 VDC

mr< D1 thium battery
DE TIME R
• DL223A 6 VDC.
BCD Port Sensor Input

terminal strips
Blank = Without BCD port .0(3000011000e1106.0e BCD Port
BCD = With BCD port 16
141~~1
17mr—rmr-1r—tr ir3r1
leeocloosoomeseeeel
Options (one option only)
Blank = Without options licaso.ocoosarooeeeeoei
RL = With remote lockout
RR = With remote reset
C3 = With three Class "C" lockouts
C4 = With four Class "C" lockouts Warranty
A two-year limited warranty on materials and workmanship is provided
Shipping Dimensions: 7-1/2 x 9-1/2 x 3-1/4 in. (191 x 241 x 83 mm). with this Murphy product. Details are available on request and are packed
Shipping Weight: I lb. (0.45 kg). with each unit.
In u r OPL-96001B
Revised 04-00
Catalog Section 05
(00-02-0029)
Pressure Gage and SWICHGAGE®

OPL Series 4-1/2 in. (114 mm) Diameter Dial
• Combination Indicating Gage and Critical
Pressure Limit Switches
• High and Low Pressure Limit Contacts
Are Visible and Adjustable
• Panel and Surface Mount Versions
• Indicating-only MURPHYGAGE® Available
• Latching Control Relay Versions Available
Ch* CE**
Description Specifications " Product Selection

The OPL Series Pressure SWICHGAGE® Case: Die cast aluminum; weatherproof. %.F Information
instruments are combination pressure indi- Contacts: See Electrical page 3, for WARNING: Selection of the proper
cating gages with adjustable low and high contact ratings. gage/SWICHGAGE® should include con-
limit switches. Limit switches can be wired sideration for the service application, the
Dial: 4-1/2 in, (114 mm) white on black,
directly to electric pilot circuits to operate medium being measured, electrical ratings,
dual scaled psi /kPa. Other dial configura-
alarrns, shutdown or start/stop of engines hazardous area requirements and general
tions available. Consult factory.
and electric motors. operating conditions. Improper selection
Surface mount or panel mount enclosure is Gage Accuracy: ±2% for the first and and/or application may be detrimental to the
available for most versions. All versions last quarters of the scale, the middle gage/SWICHGAGE®, could cause failure in
feature a 4-1/2 in. (114 mm) dial for easy half is ±1%. the operating system and possibly personal
viewing. Adjustable limit switches are Geared Movement: 302 and 304 injury or property damage. If in doubt con-
accessible from front of the SWICHGAGE® stainless steel. sult our sales/engineering staff.
Limit contacts have self-cleaning motion to Lens: Optically clear polycarbonate.
enhance electrical continuity.
Pointer: High visibility with a pointer Warranty
Other versions available (see page 2): calibration hub. A two-year limited warranty on materials
• Gage-only without contacts and workmanship is provided with this
Process Connection: Available in 1/4 NPT
(MURPHYGAGE®) Murphy product. Details are available on
and 1/2 NPT. See Table B, page 5.
• SWICHGAGE® with built-in latching request and are packed with each unit.
relay for start-stop operations. Sensing Element: Select from brome, 316
stainless steel bourdon tube. See Table B, tSpecial orden
page 5 for bourdon tubelsocket combinations. *Selected configurations are third party Usted. Consub factory for details.
**Products covered by this bullelin comply with EMC Council directive
89/336/EEC regarding electromagnebc compatibility as noted.
1
Base Models
OPLC, OPLCE and OPLG

The OPLC is a surface mounting, indicating, pressure gage and switch. Adjustable high and
low limit, ungrounded contacts are used to operate alarm, shutdown or start-stop circuits.
Pointer closure against either of the adjustable contacts completes the pilot-duty circuit. An
SPST toggle switch is provided to override the low limit contact for equipment startup.
Suitable for engines or electric motors with appropriate Murphy magnetic switch or trans-
former relay assembly.
The OPLCE features a panel mount square case. It has all the features of the OPLC
except the low limit contact lockout.
The OPLG is an indicating-only pressure
MURPHYGAGE®. Same as the OPLC
r
except without switch (limit) contacts.
OPLFC and OPLFG

The OPLFC is a panel mounting version of the °PLC. It has all of the features of the OPLC
except the low limit contact lockout. The lockout must be done externally through the con-
trol circuit or with the optional "SA" lockout. The OPLFC is typically used in control pan-
els such as for compressors, pumps, etc. This version can be environmentally sealed with
either the "ES" or "OS" options. Contact lead termination is by pigtail wires.
The OPLFG is an indicating-only pressure
MURPHYGAGE®. Same as the OPLFC except
without switch (limit) contacts. Ch* CE**
OPLBP and OPLBPE

The OPLBP is a specialized version of the OPL series designed for start-stop operation of
engines and electric motors. The pilot-duty limit switches are connected to an interna]
latching control relay for ON/OFF automation. Available for various voltages.
The OPLBPE is the same as the OPLBP except has a panel mount square case.
*Selected configurations are third party listed. Consult factory for details.
**Products covered by chis bulletin comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility as noted.
2
Electrical Dimensions
OPLC and OPLCE OPLC, OPLCE and OPLG

8.7/16 in. 3.3/8 in.
NOTE: Does not apply Lockout (214 mm) (86 mm) 1/2 NPT
Toggle Switch 7-71B in. Conduit
to model OPLG. (200 mm)
(OPLC only) (OPLCE)
1/2 NPT
4-1/32 in. Conduit
Low Limit (102 mm)
(OPLC)
Contact
Lockout
Switch 9/32 in.
(7 mm) dia.
(OPLC only)
3 hales
See Table B,
Red White Black page 5 for
Pressure
Limit Contact Connection Size
Contact Rating: 1 SPDT; Center off: 2 A, 30 VDC, Adjustment Knobs NOTE: OPLCE does not
1 A, 125 V AC pilot duty (not included with OPLG) include mounting flange.
OPLFC OPLFC and OPLFG

5-7/16 in 2-57/64 in.
NOTE: Does not apply (138 mm) (73 mm)
to model OPLFG. Mounting F
Viole 4-3/4 in.
(121 mm)
diameter
ti m
See Table B,
Page 5 for
Limit Contact Pressure
Red White Black 1/4 in. (6 mm) d'a Connection Size
Adjustment
Knobs (not é hales (3 places.) on =',..,.."--
Contad Rating: 1 SPDT; Center off; 2 A, 30 V DC, 1 A, 125 V included with OPLFG) 5-13/64 in. (132 mm)
B.c.,120r apart, clocking as shown
OPLBP and OPLBPE OPLBP and OPLBPE

BLUE
8-7/16 pulg. 3-3/8 in.
COMMON •I • (214 mm) 7-7/8 pula (B6 mm) Orificio
112 NPT
(200 mm) (OPLBPE)
•
• •
e
Orificio
1/2 NPT
(OPLBP)
9/32 pulg.
(7 mm) dia.
3 orificios
LOW
Vea la Tabla B,
(RESET)
página 5 para
Bucx ❑ medidas de las
NOTE: OPLBPE no incluye conexiones de
Botones para Ajustar Presión.
los contactos de limite. la pestaña de montaje.
Contact Rating: SPDT dry re)ay contacts; 10 A, 125 V AC.
3
Options and Accessories
P4 and P6 Options
The P4 (was PT147) option provides a remote seal mechanism to
protect the SWICHGAGE® sensing element from line pressures of NOTE: Pressure ranga
highly viscous and mildly corrosive fluids. A sealed stainless steel bele* 100 psi (689 kPa)
capillary tube, with stainless steel armor, transmits the pressure from [6.9 bar] are subject to error,
the diaphragm seal to the SWICHGAGE®. Standard capillary length if ambient temperature
verles gra l.
is 5 ft. (1.5 m). Optional lengths to 50 ft. (15 m) in 5 ft. (1.5 m)
increments are available. Oil well lead fines and pumps with highly
viscous liquids are typical applications. A 1 N'In' steel plated pulsa-
tion dampener is included.
The P6 (was PT167) option is a diaphragm sealed to a 2 NPT housing
which attaches directly to the pressure gage connection. The gage
sensing element and the diaphragm chamber are filled with a silicone
fluid so that pressure against the diaphragm causes the gage to
respond. The diaphragm housing is plated machined steel. Typical
application is for oil well lead fines. Optional* 304 stainless steel.
Ranges 100 to 5,000 psi (689 kPa to 34.5 MPa) [6.9 to 344.7 bar].
OPLFC-A-1000.OS-P4
The P4 and P6 can be ordered as optional features to the SWICH-
OPIFC-A-600-0S-P6
GAGE® or indicating-only MURPHYGAGE®. See How to Order on
pages 5 and 6.
*Meets NACE standard MR-01-75 for direct exposure to H2S service.
Tamperproof Contad Option Pulsation Dampener

• Eliminate pointer contact flutter on pressure SWICHGAGE®
and MURPHYGAGE® instruments which are subject to pul-
sating pressure from reciprocating pumps or compressors.
• Allow close high-low contact settings for more accurate pres-
sure indication and equipment control.
• Decrease wear on internal geared
movement and increase the life of
your instrument by eliminating
excessive strain and unnecessary
pointer movement.
• Available in brass, carbon steel
and stainless steel.
• Must be ordered separately.
See bulletin PD-95145B.
4
How to Order
Selecting a Model: OPLBP — S — 2 — 1000 — Ti

1. Select a Base Part Number from Table A
2. Select Bourdon Tube and Socket code from Table B
3. Select "BP" Relay Voltage code (applies to "BP" models only) from Table C
4. Select Range code from Table D"'
5. Select Options from Table E"'
(1) For metric only dials specify scale and unit of measure; example: kPa or bar.
9/ List options in alphabetical order (A to Z) followed by numeric in ascending order. Place a dash (—) between each option. See example aboye.
Table A: Base Models

OPLC SWICHGAGE®, surface mount, with low limit lockout switch Table C: "BP" Relay Voltage
OPLCE SWICHGAGE', panel mount square case Code Voltage
OPLFC SWICHGAGE®, panel mount Blank") 120 VAC
OPLBP* SWICHGAGE', surface mount, with latching control relay 2 12 VDC
OPLBPE* SWICHGAGE', panel mount square case, with latching control relay 3 24 VAC
OPLG MURPHYGAGE®, surface mount 4 24 VDC
OPLFG MURPHYGAGE®, panel mount NOTE Relay Voltage applies to "BP' models only.
* This version not covered by the CE mark. No code is required for 120 VAC voltage.
13)
Table B: Bourdon Tube and Socket

Process Range Selection Bourdon Tube and Tip Material Socket
Code Connection Tube Type Limits psi (MPa) [bar] (all joints TIG welded except "A") Material
Thru 1,000 psi Grade A Phosphor Bronze Tube
A(41 1/4 NPT Drawn C-Tube (6.89 MPa) [68.95 bar] (Brass Tip, Silver Brazed) Brass
Thru 1,000 psi

1/4 NPT Drawn C-Tube (6.89 MPa) [68.95 bar]
R15116) 316 Stainless Steel 1019 Steel
1,500/20,000 psi (10.3/138 MPa)
1/2 NPT Drawn Helical [103.42/1378.94 bar]
Thru 1.000 psi

1/4 NPT Drawn C-Tube
(6.89 MPa) [68.95 bar] 316
S161 316 Stainless Steel
1,500/20,000 psi (10.3/138 MPa) Stainless Steel
1/2 NPT Drawn Helical [103.42/1378.94 bar]
0) Standard hru 1,000 psi (6.89 MPa) [68.95 bar].

0) Standard 1,500 psi (10.3 MPa) [103.42 bar] thru 20,000 psi (138 MPa) [1378.94 bar].
(6)Optional all ranges.
5
Table D: Ranges
Code Vacuum/psi kPa/MPa bar
Dials
30HV6OH 30' Hg/Vac-60" HglPress. -101 kPa-203 kPa -1.01-2.03 All dials are dual scaled psi and kPa/MPa. Single scale dials and custom dials
30V 30" vac-0 psi -101 kPa-0 kPa -1.01-0 available. Additional charges may apply.
301115 30" vac-15 psi -101 kPa-103 kPa -1.01-1.03
30V30 30" vac-30 psi -101 kPa-207 kPa -1.01-2.07
Gages
30V100 30" vac-100 psi -101 kPa-689 kPa -1.01-6.89
All 4-1/2 inch (114 mm) SWICHGAGE® devices are available for Class I,
30V200 30' vac-200 psi -101 kPa-1.38 MPa -1.01-13.79
Division 1, Groups C & D hazardous applications.
30V300 30' vac-300 psi -101 kPa-2.07 MPa -1.01-20.68
Division 2 locations can also be covered by our Non-Incendive or Intrinsically
15 0-15 psi 0-103 kPa 0-1.03
Safe systems. See the full catalog or contact any Murphy representative for
30 0-30 psi 0-207 kPa 0-2.06 complete details.
60 0-60 psi 0-414 kPa 0-4.13
100 0-100 psi 0-689 kPa 0-6.89
160 0-160 psi 0-1.10 MPa 0-11
200 0-200 psi 0-1.38 MPa 0-14
300 0-300 psi 0-2.07 MPa 0-20
400 0-400 psi 0-2.76 MPa 0-28
600 0-600 psi 0-4.14 MPa 0-40
1000 0-1000 psi 0-6.89 MPa 0-70
1500 0-1500 psi 0-10.34 MPa 0-100
2000 0-2000 psi 0-13.79 MPa 0-140
3000 0-3000 psi 0-20.68 MPa 0-200
5000 0-5000 psi 0-34.48 MPa 0-350
10000 0-10,000 psi 0-68.95 MPa 0-700
20000 0-20,000 psi 0-137.90 MPa 0-1350
Table E: Optionst Shipping Information**

Shipping Weights:
Option Description Option Description
OPLC: 5 lbs 9 oz (2.5 kg)
BC Back connected bourdon tube P6 (PT167) PT167 pressure
OPLG: 5 lbs 6 oz (2.4 kg)
transmitter, direct mounting
CC 1/2 NPT conduit connection OPLFC and OPLCE: 3 lbs 4 oz (1.5 kg)
ES Environmentally sealed P6S (PT16755) PT167 pressure
OPLFG: 3 lbs 4 oz (1.5 kg)
transmitter, direct mounting, 304
EX Explosion-proof: SWICHGAGE' OPLBP and OPLBPE: 5 lbs 11 oz (2.6 kg)
stainless steel
enclosed within explosion proof
case; Class I, Div. 1, Groups C & D T1 (TPC1) Tamperproof, knob locks
Shipping Dimensions:
EL (EXLC) Explosion-proof less case TA (TCA) Tickler contact
OPLC, OPLG and OPLFG:
LC Less case 9 - 1/2 x 9- 1/4 x 5 - 3/4 ir,. (241 x 235 x 146 mm)
OS Oil sealed case OPLFC and OPLCE:
P4 (PT147) Pressure transmitter with 9- 1/4 x 8-1/4 x 5 -1/2 in. (235 x 210 x 140 mm)
5 ft. (1.5 m) capillary* OPLBP and OPLBPE:
P4L PT147 less pulsation dampener* 9-1/4 x 8-1/4 x 5- 1/2 in. (235 x 210 x 140 mm)
* For capillary greater than 5 ft., specify
in 5 ft increments following ** Some options could alter shipping weights and
designator; example: P415 dimensions. Consult factory.
toptions not available on all models or configurations.
In order to consistently bring you the highest guality, full featured products, we reserve the right to changa our specifications and designs at any time.
FRANK W. MURPHY MANUFACTURER P.O. Box 470248; Tulsa, Oklahoma 74147; USA tel. (918) 627-3550 fax (918) 664-6146 e-mail salesehnurphy.cam http://wmv.fwmurphy.com
FRANK W. MURPHY MFR. MURPHY DE MÉXICO, S.A. DE C.V. MURPHY SWITCH OF CALIFORNIA
CONTROL SYSTEMS & SERVICES DIVISION Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje 41343 12th Street West
*reu rp P.O. Box 1819; Rosenberg, Texas 77471; USA San Luis Potosí, S.L.P.; México 78384 Paimdale, California 93551-1442; USA
tel. (281) 342-0297 fax (281) 341-6006 tel. +52-48-206264 fax +52-48-206336 tel. (661) 272-4700 fax (661) 947-7570
e-mail sales@fwmphy.com e-mail ventasmex@murphymex.com.mx e-mail sales@murphymitch.com
http://vrommurphyswitch.rom
Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. No. 2 Tuas South Street 2, MACQUARRIE CORPORATION
tel. +44 1722 410055 fax +44 1722 410088 Sprinters Bldg., 802-01/02 1620 Hume Highway;
USA-ISO 9001 FM 28221 http://www.fwmurphy.co.uk tel. +65 863-1398 fax +65 863-0208 tel. +61 3 9358-5555 fax +61 3 9358-5558
UK-ISO 9002 FM 29422
e-mail fwmsales@fwrourphy.com.sg e-mail murphy@marguarrie.com.au
tel. +33 1 30 762626 fax +33 1 30 763989
Printed in U.S.A.
6
MDTM-8911B
Dual Temperature SWICHGAGE® Revised 07-99
Catalog Section 10
(00-02-0040)
Model Series MDTM89

• Monitor inputs from two
thermocouples
• Adjustable switch
trip point for each input
• FET or SCR output
• Power from CD ignition or
120 VAC or 12/24 VDC
VCMIIMILIT UNE
• Types"J"or"K"ungrounded
thermocouples
THIP. P.1
• Digital readings in
Fahrenheit or Celsius
*When used with approved ignition or
12-24 VDC. Contad Murphy for details.
* *Approved for CD ignition, 80-250 VDC.
Description
Murphy's model MDTM89 is an electronic, dual-temperature Automatic Coid Junction Reference
monitor. It monitors two thermocouples, displays the Cold junction reference point compensation is an integral
temperature of the thermocouple selected, and has feature of the monitor. The compensator circuit monitors
adjustable trip points for each input. A toggle switch provides case temperature and automatically compensates for
for selection of the thermocouple to be displayed and/or the changes in ambient temperatures. Compensation will allow
temperature trip point to be checked/adjusted. If either trip maximum of 2 degrees change in the temperature reading
point is reached, the associated output "turns on" and can be from 32 to 122°F (0 to 50°C).
used as a control signal, or to initiate alarms and/or
shutdown. Open Thermocouple Input
A "Push to Read" button, located below the selector An open thermocouple input forces the monitor into upscale
switch, allows the operator to check the trip point and to see overrange. The monitor indicates an overrange by displaying
its value as adjustments are made. Two potentiometers, one the numeral 1 (one) in the lett most digit of the display. An
on each side of the thermocouple selector switch, are overrange will turn on the high trip point output.
provided for field-adjustment of the trip points.
There are four basic models. Two of the models are Trip Point Operation
powered by capacitor discharge ignition, and have either an Monitored trip points are independent of the thermocouple
FET or an SCR output. One model operates from 12 or 24 selector switch. Both set points are always active.
VDC and has an FET output. One model operates from 120 When the thermocouple temperature reaches the trip point
VAC by use of an isolation module and has an FET output. temperature, the MDTM89 is triggered. After approximately
Standard display is in degrees Fahrenheit; degrees Celsius 0.5 seconds the trip point output "turns on".
is optional. Trip points are set by depressing the "Push to Read" push
button while rotating a trip point potentiometer until the
Applications desired trip point temperature is displayed.
Applications include the following:
• Compressor suction/discharge temperature Continuous & Trip Point Display
• Engine/compressor jacket water temperature The selector switch is used to select the thermocouple or trip
• Engine exhaust temperature point temperature to be displayed. The selected temperature
• Compressor cylinder temperature is continuously displayed during normal operation.
• After cooler temperature Depressing the "Push to Read" push button displays the trip
• Bearing temperature point temperature of the selected thermocouple.
Thermocouple Type
Either "J" or "K" type UNGROUNDED THERMOCOUPLE is
accepted. Specify type in part number for each MDTM89 unit
(see How to Order information on back page).
Order thermocouples as a separate

Specífications
Power Requirements (Operating Voltages): Storage Temperature: -40 to 300°F (-40 to 150°C).
MDTM89-A: 100 to 3501t VDC, CD ignition, negative Case: Die cast aluminum.
ground (FET outputs). Reset Differential: FET models: Decreases 3 Degrees (°F or °C).
MDTM89-B: 100 to 350tt VDC, CD ignition, negative or SCR mode!: tum input power off fo reset.
positive ground (SCR outputs). Measurement Range: Monitor Range 0-1999°F or °C (specify "F'
MDTM89-C: 12 to 24t VDC, negative ground, 15 milliwatts or "C" in part number).
(FET outputs). Accuracy: With J-type thermocouple: from 150-1200°F (66-649°C)
MDTM89-D: 120 VAC (MDTM89-C with 120 V isolation module #IT-1) .±1.5% of reading. With K-type thermocouple: from 400-2000°F
(FET outputs.) Model NOT approved by CSA or Factory Mutual. (204-1076°C) 1.1.5% of reading. At calibration temperature.
Power Consumption: CD ignition: 350 pa @ 100V; Laboratory Approvals: CSAt and Factory Mutualtt approved for
120 VAC: 0.6 watts; 24 VDC: 0.5 watts. Class I, Division 2, Group D, hazardous locations).
Outputs: Model B: output tures on aboye trip point; output tures Thermocouple Lead Length: 150 ohm lead resistance affects
off when power is switched off; two (2) isolafed SCR outputs, monitor accuracy less than 1°.
0.5 amp @ 250 VDC. Trip Point Accuracy: ±3°F (±2°C) of reading.
Models A, C and D: output tures on aboye trip point; output Trip Point Adjustment Range: 0-1999 Degrees.
tures off below trip point; two (2) isolated FET outputs, 0.5 amp Shipping Weight: 48 ozs (1.4 kg).
250 VDC. Shipping Dimensions: 10 x 9-'12 x 6 in. (254 x 241 x 152 mm)
Ambient Cold Junction Compensation Range: (When usad with approved ignitions or 12-24 VDC. Contact Murphy for details.
32 to 122°F (1°C from O to 50°C). tt Approved for CD ignition, 80-250 VDC.
Operating Temperature: -4 to 158°F (-20 to 70°C).
Dimensions How to Order

4-3/4 in. 4-1/4 in. To order the MDTM89, please use the diagram below.
(121 mm) 1.1-- (108 mm) Part number example: MDTM89-F-A-J
MDTM89-
IIa Calibraban Type of ungrounded thermocouple
F: Fahrenheit fo be used; "J" or "K".
a C: Celsius
O 0
• Powered by and type output:
A: CD ignition, 100-350 VDC, output by FET (Field Effect Transistor,
0.5 A @ 250 VDC maximum).
5-1/2 in. —0- 4 in. B: CD ignition, 100-350 VDC, output by SCR (Silicon Controller
(140 mm) (102 mm) Rectifier, 0.5 A 1250 VDC maximum).
4-3/4 in. C: 12 to 24 VDC, 15 mw, output by FET
(121 mm)
D: 120 VAC, output by FET (same as "C" with a
120 VAC-24 VDC power supply WIT-11)
Mounting Hole
NOTE: "D" version is NOT approved by CSA or Factory Mutual. "B" version for
120° use with Electromechanical TATTLETALE° annunciators. Models A, C and
120° for use with $ELECTRONIC• or similar solid state annunciators.
1/4 in. MDTM89 Interface Capabilities

(6 mm) Mode! Power Source Rating
2-39/64 in. radius Typical LCDT CD Ign., 120 VAC, 12/24 VDC CI.1, Div.1, Gr.D , Haz. areas*
(66 mm) diameter
S1501 120 VAC or 12/24 VDC Div.1, Gr.D , Haz. areas*
MARK 11 CD Ignition, pos. or neg. gmd CI.1, Div.2, Gr. D , Haz. areas**
TATTLETALE• CD Ign., 120 VAC, 12/24 VDC Non-Hazardous areas
Warranty PLC's, various non-Murphy annunciators—contact factory.
A two year limited warranty on materials and workmanship is given *An isolation barrier is needed between the MDTM89 and an Annunciator rated for
with this Murphy product. Details are available on request and are Class 1, Division 1, Group D, Hazardous Areas.
packed with each unit. **When used with approved ignition. Contact Murphy for details.
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
■ Frank W. Murphy, Ltd. ■ Murphy de México, S.A. de C.V.
Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
Since 1939 tel. +44 1722 410055 fax +44 1722 410088 tlx 477088 San Luis Potosi, S.L.P.; México 78384
e-mail sales@fwmurphy.co.uk tel. +52-48-206264 fax +52-48-206336
■ Frank W. Murphy Manufacturer
P.O. Box 470248; Tulsa, Oklahoma 74147; USA ■ Frank W. Murphy Pte., Ltd. e-mail murmexsl@infosel.net.mx
tel. (918) 627-3550 fax (918) 664-6146 26 Siglap Drive; Republic of Singapore 456153 ■ Murphy Switch of California
e-mail fwmurphy@ionet.net tel. +65 241-3166 fax +65 241-8382 P.O. Box 900788; Palmdale, California 93590; USA
e-mail fwmsales@fwmurphy.com.sg tel. (805) 272-4700 fax (805) 947-7570
■ Frank W. Murphy Southem Division e-mail sales@murphyswitch.com
P.O. Box 1819; Rosenberg, Texas 77471; USA ■ Mit/pfmk Pty., Ltd.
tel. (281) 342-0297 fax (281) 341.6006 1620 Hume Highway; Campbel1field, Vic 3061; Australia 11Frank W. Murphy France
e-mail murphysdOintertex.net tel. +61 3 9358-5555 fax +61 3 9358-5558 tel. +33 1 30 762626 fax +33 1 30 763989
Printed in U.S.A. 0889804
T-94031B
FRANK W. Revised 10-99
Catalog Section 10
(00-02-0048)
20 and 25 Series Temperature SWICHGAGE®

20T Series
2 and 2-1/2 in. (51 and 64 mm) Dial
shown
• Combination Indicating Gage and Limit Switch
• Critical/High Temperature Limit Switch Is
Visible and Adjustable (Most Models)
• Switch Can Activate Alarms and/or
Shut Down Equipment
• Contact Grounds Through Case CE**
Description
The 20 Series (2 inch/51 mm dial) and the 25 Series Bezel: Polished stainless steel, standard; others are 20T1 and 25TL SWICHGAGE.
(2-1/2 inch/64 mm dial) SWICHGAGE° models are available (see How to Order). For use on Ford Wor]dwide engines. Supplied with
diaphragm-actuated, temperature-indicating gages, Pointer: Tempered nickel silver. special sensing bulb.
with built-in electrical switches for tripping alarms Lens: Polycarbonate, high-impact, 20T0 SWICHGAGE®
and/or shutdown devices. Same as 20T with a special dial for Oil Temperature.
Sensing Element: Beryllium copper diaphragm.
Ranges are available from 32-120°F (0-45°C) thru
Capillary: PVC armored copper; 4 ft. (1.2 m) 20TE and 25TE SW1CHGAGr
300-440°F (160-220°C). 20TE (was 20ESR) and 25TE (was 25ESR).
Galvanized and stainless steel armor optional.
The gage mechanism is enclosed in a steel case Models with intemal SPDT snap-switches, instead
coated to resist corrosion. A polycarbonate, Break- Sensing Bulb: Copperl<
of the single pole/pointer contact(s). When the
resistant lens and a polished, stainless steel bezel Gage Accuracy: See accuracy chart, on page 2. switch clones on rising temperature, it becomes Set.
help protect this rugged, built-to-last instrument. Maximum Temperature: See Temperature Ranges As temperature decreases the switch Resets.
These vapor actuated gages feature a sealed capil- and Factory Settings table on page 2.
20TABS and 25TABS SW1CHGAGE
lary tube and a sensing bulb. When subjected to Adjustable Limit Contact (20T and 25T): Same as 20/25T with interna] SPDT snap-switch for
heat, the liquid in the sensing bulb changes to vapor SPST contact; pilot duty only, 2 A @ pre-alarm.
creating pressure against the diaphragm mechanism. 30 VAC/ VDC; Ground path through encase-
The diaphragm translates this vapor pressure into a ment. Normally Closed (NC) when the high limit is Bearing Temperature
mechanical gage reading. met. Normally Open (NO) when pointer is in normal 20TB SW1CHGAGr
For series 20T and 25T, the gage pointer acts as a operatinglange. Contacts are gold flashed silver. Features special sensing bulb for saddle
temperature indicator and as one switch pole which Limit Contact Adjustment: by a 1/16 in. hex bearing temperature.
completes a circuit when it touches the adjustable wrench thru 100% of the scale.
Cylinder Head Temperature
limit contact. Contact(s) are grounded through the Limit Contact Wire Leads: 18 AWG (1.0 mm2) x
SWICHGAGE® case. They have self-cleaning 20TH and 25TH SWICNGAGE®
12 in. (305 mm).
motion to enhance electrical continuity. 20TH (was 20T12133) and 25TH (was 25TL8133).
Snap-Switch Rating (20TE and 25TE): For use on Air Cooled engines,
Models 20TE and 25TE have interna] snap-acting SPDT, 3 A @ 30 VDC inductive; 4 A @
SPDT switches. 125 VAC inductive. Direct Mount Models
Gage-only models, without contacts Snap-Switch Wire Leads: 20 AWG (0.75 trun9x 20TD SW1CHGAGr
(MURPHYGAGE°) are also available. 12 in. (305 mm). Same as 20T. Available ranges: 220°F (104°C ) or
Unit Weight: 20 Series: 12.7 oz. (0.39 kg). 250°F (121°C). Includes 1/4 x 4 in. (6 x 102 mm)
Applications 25 Series Models: 13.8 oz. (0.43 kg). sensing bulb.
Industrial engines and equipment in Oil Field, 20SD SWICHGAGr
Marine, Irrigation, Construction and Trucking Unit Dimensions: 20 Series: 4-3/4 x 4-3/4 x 2-3/4 in.
(121 x 121 x 70 mm). 25 Series Models: 4-3/4 x Same as 20T. Available ranges: 220°F (104°C) or
industries. Monitoring Engine Coolant, Crankcase 250°F (I21°C). Includes 11/32 x 1-1/2 in. (9 x
Oil, Transmission Oil. 4-3/4 x 3 in. (121 x 121 x 76 mm).
38 mm) sensing bulb.
Specifications Base Models Gage-Only Models
Dial: White on black; U.S.A. standard scale is dual Coolant or Oil Temperature 20TG and 25TG MURPHYGAGE'r
scale °F/°C; others available (see How to Order). 20T and 25T Series SW1CHGAGr Gages without contact(s).
Case: Plated steel; mounting clamp included (except For there models the gage pointer makes with an * For optional capilla), lengths, engine adaptors, sensing bulbs
for direct mounting models). adjustable contad to complete a pilot-duty circuit. and range combinations, see Murphy bulletin T-8428B.
** Products cover by this bulletin comply with EMC Council
directive 89/336fEEC regarding electromagnetic compatibility
as noted.
Dimensions
20 Series Models (typical) 25 Series Models (typical)
-4-- 2-15/64 in. (57 mm) -4— 2-9/32 in. (58 mm)-1.- 3-1/8 in. (79 mm) F4-- 2-9/32 in. (58 mm)
..4_1-5/16 in. CapillarytJ

2-1/16 in. (52 mm)
Mounting hole dia.
1 (33 mm)
4 ft. (1.2 m)
long
Contact
Adiustment 11151111 ~1.allillhil.
111 2-11/16 in. (68 mm)
1/16 in. hex nal Mounting hole dia.
/ in.
1/2 NPT (38 mm) 8-18 U.N.F. Contact
Adapter Nutt Senaing Bulbt Union Nut Adjustment
(.
1/16 in. hex 1-1/21n.
1/2 NPT (38 mm) 518-18 U.N.F.
¡Standard combinations. See Murphy bulletin T-842813 for optional sensing bulb, engine adaptors and capillaiy combinations. Adapter Nur," Senaing Bulbt Union Nut
Temperature Ranges and Factory Settings

NOTES
1.Values in O are mathematical conversions from °F to °C-they do not reflect actual second scale range. U.S.A. standard scale is °F/°C.
2. For models 20TE and 25TE; the switch trip point cannot be set at either the low or high extreme of the scale. The trip point must allow for the reset differential.
3. For adjustable switch models, the trip point is adjustable only over the upper half of the scale.
Ranges Available Max. Temp. Std. Settmgs* HifLo Settings 20TABS and 25TABS Settings
Dual Scale Dial Single Scale Low High Alarm** Shutdown
°Fahrenheit (°Celsius) °Celsius only °F (°C) °F (°C) °C only °F (°C) °F (°C) °F (°C) °C only °F (°C) °C only
32 -120 (0 - 49) — 325 (163) 110 (43) — 32 (0) 110 (43) 100 (38) — 110 (43) —
32 -160 (0 - 71) 0 - 70 325 (163) 150 (66) 66 32 (0) 150 (66) 140 (60) 60 150 (66) 66
130 - 220 (54 -104) 45 -100 325 (163) 210 (99) 85 160 (71) 210 (99) 200 (93) 80 210 (99) 85
130 - 250 (54 -121) 50 -120 325 (163) 210 (99) 97 160 (71) 210 (99) 200 (93) 95 210 (99) 100
140 - 300 (60 -149) 60 -140 325 (163) 275 (135) 130 200 (93) 275 (135) 265 (129) 125 275 (135) 130
160 - 320 (71 - 160) 70 -160 500 (260) 300 (149) 150 200 (93) 300 (149) 290 (143) 145 300 (149) 150
180 - 350 (82 -177) — 500 (260) 330 (166) — 240 (116) 330 (166) 320 (160) — 330 (166) —
300 -440 (149 - 227) — 500 (260) 400 (204) — 300 (149) 400 (204) 390 (199) — 400 (204) —
* Standard setting for 20T, 25T, 20TE and 25TE models.
** SPDT snap-switch is the alarm switch.
Temperature Accuracy Chart

Temperature Range Lower V3 of Scale Middle 1/3 of Scale Upper V3 of Scale
32 to 120°F (0 to 49°C) ± 12°F (± 6°C) ± 5°F (± 2.4°C) ± 6°F (± 3°C)
32 to 160°F (O to 71°C) ± 20°F (± 10°C) ± 8°F (± 4.4°C) ± 7°F (± 4°C)
130 to 220°F (54 to 104°C) ± 6°F (± 3°C) ± 3°F (± 1.6°C) ± 4°F (± 2°C)
130 to 250°F (54 to 121°C) ± 9°F (± 5°C) ± 5°F (± 2.4°C) ± 4°F (± 2°C)
140 to 300°F (60 to 149°C) ± 10°F (± 5.2°C) ± 6°F (± 3°C) ± 5°F (± 2.4°C)
160 to 320°F (71 to 160°C) ± 10°F (± 5.2°C) ± 5°F (± 2.4°C) ± 5°F (± 2.4°C)
180 to 350°F (82 to 177°C) ± 12°F (± 6°C) ± 5°F (± 2.4°C) ± 5°F (± 2.4°C)
300 to 440°F (149 to 227°C) ± 9°F (± 5°C) ± 5°F (± 2.4°C) ± 4°F (± 2°C)
Maximum Temperature RANGE MAXIMUM PROCESS TEMPERATURE

8250° (1201 120% OF FULL SCALE
MAXIMUM AMBIENT TEMPERATURE: -40° (-40°) thru 150° (66°) 300° (1401 350° (198°)
11320°(160°) 120% OF FULL SCALE
Magnetic Switch
INDUCTIVE AND HIGH CURRENT LOADS REQUIRE THE USE OF A TATTLETALE' Magnetic Switches show the cause of shutdown for applications
MAGNETIC SWITCH. The SWICHGAGE1 contacts are for light-duty electri- that include: capacitor discharge or magneto ignitions, battery systems and elec-
cal switching to operate alarms or control devices. Murphy manufactures the tric motor driven equipment. Typical wiring diagrams are shown below.
Magnetic Switch for protection of the light-duty SWICHGAGE' limit contacts.
20T Temperature 20P-F Pressure 20T-F Temperature 518PH Magnetic Switch

SWICHGAGE* 117 Magnetic Switch SVVICHGAGE. SWICHGAGE.
svn Sin
N.O. SW1CHGAGE•
instruments
Energized To Run Devices Y-Y Energhted To Run Devices

—
Battery
N.C. swttches option
rarri(
cr=0
Pre-Alarm Using 20/25TABS

The 20TABS and 25TABS feature a standard limit contact for high temperature and the shutdown circuit will be completed (see the typical diagram below for
equipment shutdown. ft also has an interna] SPDT snap-switch to signal an alarm reference). The front contact shutdown limit setting (which is adjustable) and the
before shutting down. When the ]ow gide of the snap-switch trips (preset point), snap-switch are preset at the factory. Refer to "Temperature Ranges and Factory
on rising temperature, the switch completes a circuit to activate an alarm. If the Settings" table on opposite page for settings. For alternative alarm before shut-
temperature continues to increase, the face-adjustable pointer contad will make down, see Magnetic Switch model 760A or 761APH.
518PH
Alarm Before 20TABS TATTLETALE°
Shutdown SWICHGAGE° Magnetic Switch
Mini-Siren°
Shutdown DevIce Opens círcult to J

or Ignttlon Circutt shutdown engin.
Typical Interna! Wiring Diagrams

Pointer shown in the shelf position. Pointer type contact rating: pilot duty 2 A @ 30 VAC/VDC.
Snap-acting switch rating: 3 A @ 30 VDC inductive. 4 A @ 125 VAC inductive.
Pointer Type "HL" Hi-Lo ABS TE

Contact Option Models Models
N.C. (RED) N.C. (RED)
COM, (WHITE) COM. (WHITE)

.11 / N.O. (BLACK) N.O. (BLACK)
\/
LOW ./HIGH HIGH
RED BLACK BLACK

–= Case Case
ground Case Ground Case Ground
ground
How to Order
To order, use the diagram below. List options in ascending alphabetical order (A-Z). Example: 20T-IP1-250-4.
Base Model
Adapter Nutsttt
20T 20TH 25TL
1/8 = 1/8-27 NPT Metric
20TL 20TD 25TE
1/4 = 1/4-18 NPT M10 = 10 mm x 1.5
20T0 20SD 25TABS
3/8 = 3/8-18 NPT M12 = 12 mmx 1.5
20TE 20TG 25TH
25TG 3/8B = 3/8-19 BSPT M14 = 14 mm x 1.5
20TABS 25T
20TB 3/8K = 3/8 NPSF M16 = 16 mm x 1.5
— = 1/2-14 NPT" M18 = 18 mm x 1.5
1/2B = 1/2-BSPT M20 = 20 mm x 1.5
1/2K = 1/2 NPSF M22 = 22 mm x 1.5
Options
5/8 = 5/8-18 UNF M24 = 24 mm x 1.5
B1 = Black bezel 3/4 = 3/4-14 NPT tttspecific adapter nut must
B2 = Bezel 05051857 (was "HP") 3/4U = 3/4-16 UNF match the sensing bulb.
B3 = Bezel 05051836 (was "HBB") 7/8 = 7/8-9 UNC TiftStandard.
F = "FS" contact (includes "ES" as appropriate)
HL = High and low contacts
= illumination (for options, see chart below) Temperature Capillary Armor Type and Length
IP1 = Light pipe illumination, 12 VDC
Capillary Armor Type
IP2 = Light pipe illumination, 24 VDC
Blank = PVC armor, copper capillary
K = Knob adjusting face contact
S = Stainless steel armor, copper capillary
OS = Oil sealed (Silicone Oil)
UA = Temperature bulb style A (10050166)* Capilla!), Length (specify atter capillary type; example: "S4")
UB = Temperature bulb style B (10010061)* 4 = 4 ft. (1.2 m)
UC = Temperature bulb style C (10010060)* Specify other length = Available in 2 ft. increments thru 20 ft.;
UD = Temperature bulb style D (10000286)* 5 ft. increments aboye 20 ft. (0.5 metres increments from 1.5-10
UE = Temperature bulb style E (10010084)* metres; 2 metre increments thru 34 metres. Specify "M" follow-
ing length, i.e. 1.5M.)
UF = Temperature bulb style F (10000577)*
UG = Temperature bulb style G (10000578)*
UH = Temperature bulb style H (10002466)*
UJ = Temperature bulb style J (10051153)* Rangett
UK = Temperature bulb style K (10054886)*
Dual scale (°F/°C) Single scale (°C)
t Options not available on all models or configurations, °F °C
* Specify optional bulb ONLY when not included as standard for 120 = 32-120 0-49 70C = 0-70°C
temperature Base Model, scale/range or capillary length.
160 = 32-160 0-71 100C = 45-100°C
220 = 130-220 54-104 120C = 50-120°C
250 = 130-250 60-121 140C = 60-140°C
Illumination Options
IP1 /1P2 I 300 = 140-300 60-149 160C = 70-160°C
x x' 320 = 160-320 71-160
20 Series
350 = 180-350 82-177
25 Series N/A x2
440 = 300-440 149-227
'Can be used with standard Clamp Lite Assembly
(12 V= 05702176; 24 V= 05702177). ttconsult factory for availability of dials other than °F/°C. Select scale
so your normal operating temperature is in the upper half of the scale.
2Order Lamp and Socket Assembly separately
(12 V= 05010198; 24 V= 05010199).
Warranty
A two-year limited warranty on materials and workmanship is given with Chis Murphy product. Details are available on request and are packed with each unit.
In order to consistently trring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
FRANK W. MURPHY MANUFACTUFtER P.O. Box 470248; Tulsa, Oklahoma 74147; USA tel. (918) 627-3550 fax (918) 664-6146 e-mail sales@fwmurphy.com http://vrmv.fivmurphy.com
■ FRANK W. MURPHY MFR.-Control Systems & Services ■ MURPHY DE MEXICO, S.A. DE C.V. ■ MURPHY SWITCH OF CAUFORNIA
ti joy
a FRANK
l ir,.ms P.O. Box 1819; Rosenberg, Texas 77471; USA Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje 41343 12th Street West
Since 1939 n'A tel. (281) 342-0297 fax (281) 341-6006
e-mail sales@fwmurphy.com
San Luis Potosi, S.LP.; México 78384
tel. +52-48-206264 fax +52-48-206336
Palmdale, California 93551-1442; USA
tel. (661) 272-4700 fax (661) 947-7570
e-mail ventas@murphymex.com.mx e-mail sales@murphyswitch.com
■ FRANK W. MURPHY, LTD.
http://www.murphyswitch.corn
Church Rd.; Laverstock Salisbury SP1 102; U.K. ■ FRANK W. MURPHY PTE., LTD.
tel. +441722 410055 fax +44 1722 410088 No. 2 Tuas South Street 2, ■ MACQUARRIE CORPORATION
e-mail sales@hwourphy.co.uk Sprintecs Bldg., *02-01/02 1620 Hume Highway;
http://vnwi.fwmurphy.co.uk Singapore 638042 Carripbellfield, Vic 3061; Australia
USA—ISO 9001 FM 28221
UK-150 9002 FM 29422 tel. +65 863-1398 fax +65 863-0208 tel. +61 3 9358-5555 fax +61 3 9358-5558
■ FRANK W. MURPHY FRANCE
Printed in U.S.A.
e-mail hvmsales@Nnnurphy.00ntsg e-mail murphy@macquarrie.coin.au
tel. +33 1 30 762626 fax +33 1 30 163989
SHD3-97050B
+ -=
na■._1.'-.I-g
'"."31111
,. Revised 05-00
Catalog Section 20
(00-02-0287)
Digital Tachometer and Hourmeter with

Adjustable Overspeed Trip Point
SHD30 Model
• Normally Open and Normally Closed Overspeed
Alarm or Shutdown Switch (Standard)
• RPM Data and Power Supplied by Magnetic
Pickup or Capacitor Discharge (CD) Ignition
• Accurate to ±0.5% of Display Reading
• Hours Can Be Preset and Reset to Zero
• Approved for Class I, Division 2,
Groups C & D Hazardous Areas
Muirfly
orDprr
tv
airsg 20-08-0258
troirrIzIrjailijMurp
NRTLJC*
Description Applications Backup Batteries: 2 replaceable, long life

The SHD30 is a microprocessor-based tachometer • Gas Compressors • Industrial Engines Lithium batteries, 3.5 V, 350 mA power.
and hourmeter with an overspeed trip point. The Shelf life expectancy 10 years.
• Oil Field Equipment • Generators
trip point can be connected as either a form "c " Operating Temperature;
relay output or as a normally open SCR output -4° to 158°F (-20° to 70°C).
Easy-to-Calíbrate
for alarm or shutdown on overspeed. The SHD30 calibration is done by entering the Storage Temperature:
The SHD30 features a panel-mounting design, plas- number of pulses per engine revolution using the -40° to 300°F (-40° to 150°C).
tic enclosure that is 5-1/16 (129 mm) long and Pulses per Revolution and Overspeed Setpoint Case Material: Plastic.
4-1/4 in. (108 mm) high. membrane keys, on the faceplate. The number of Ignition Frequency Range: 3 to 666 Hz.
The SHD30 power and RPM data are supplied by pulses is determined by the number of cylinders,
Magnetic Pickup Frequency Range: 1 to 10 kHz.
either a magnetic pickup or a capacitor discharge cycles and ignition features. It is also determined
(CD) ignition. The hourmeter is adjustable to a pre- by the number of ring gear teeth of the engine's Overspeed Output:
set time and resettable to zero. Should power be lost, flywheel on a magnetic pickup system. Connected to S.C.R. (Silicon Controlled
on-board batteries maintain the run hours display Presetting and resetting running hours is done from Rectifier) terminals:
and allow for resetting the overspeed relay output. 0.5 A, 350 VDC continuous.
the back and front of the SHD30.
Connected to Form "C" Relay terminals:
Basic Operation Specifications Relay Contact, 0.5 A, 30 VDC, 125 VAC resistive
When a tach signal is present the SHD30 displays Tachometer Accuracy: ±0.5% of the display
Power input:
rpm. When a tach signal is not present, the display reading or ±1 RPM whichever is greater.
is blank unless the Read Hours membrane key, on CD ignition: 90 to 350 VDC.
150 ItA typical @ 90 VDC; Hourmeter Range: O to 65535 hrs.
the faceplate is pressed and held.
300 pA @ 350 VDC. Hourmeter Accuracy: ±15 minutes per year.
The five-digit, liquid crysta] display is updated every
Magnetic Pickup; 5 to 120 Vrms. Laboratory Approvals: CSA (Canadian
second. The run hours, overspeed set point and
325 pA typical @ 5 Vrms, 100 Hz; Standards Association) approved for Class I,
current pulses per engine revolution can be dis-
450 pA typical @ 5 Vrms, 1 kHz; Division 2, Groups C & D hazardous arcas.
played by manipulating the membrane switches.
1 mA typical @ 5 Vrms, 5 kHz; Shipping Weight : 1 lb ( 0.5 kg).
Run hours can be displayed even after power is 2 mA typical @ 5 Vrms, 10 kHz;
lost. The run hours display can be configured to 15 mW max. @ 5 Vrms, 10 kHz Shipping Dimensions: 9-1/4 x 8-1/4 x 5-1/4 in.
alternate with the RPM display. 2.8 W max. @ 120 Vrms, 10 kHz. (235 x 210 x 133 mm),
* The NRTIJC indicator adjacent io the CSA Mark sIgniiles that Ose product has been evaluated lo the a pplicable ANSITUL and CSA Standards, for use in the U.S.
and Canada. NRTL/C, Le. NationalIy Recognlzed Testing Laboratory, h a designadon granted by the U.S. Otaupatlon! Safery and Fred, h Administration (OSHA).
Dimensions Typical Wiring Diagram
Front View Side View

T.0
5-1/16 in. CD Ignition
(129 mm) 90-350 VDC Form "C" Relay Output
c. 0.5 A, 30 VDC,
+ 90-350P2 N.c. 125 VAC resist.
See Waming below.
NEG Ovrn PEED
SC Rs II N.O. SCR Output
o 4-1/4 in.
(108 mm) Shield
5120 Vrms 0a 0,09..MEED — 0.5 A, 350 VDC cont.
Place momentary
OR "n
;97 ~ RESET Dumper to reset
runnIng hours.
Magnetic Pickup
5 Vrms -120 Vrms
Mounting Hole WARNING: In hazardous areas the overspeed relay contact
3-1/8 in.
2 in. 2 in.
(51 mm) r(51 mm) /\ is certified for use ONLY with Murphy non-incendive or intrin-
sically safe products. In non-hazardous areas overspeed relay
contact may be used to switch electromechanical TattletalC or Magnetic
2 in.
(79 mm) (51 mm) Switches that do not exceed the relay contact rating: 1 A, 30 VDC; 0.3 A,
diameter 110 VDC; 0.5 A, 125 VAC. However, the preferred output to switch
electromechanical Tattletaleor Magnetic Switches is the N.O. SCR.
1.1/2 in.
3/16 in
(5 mm) (38 mm)
diameter, Refer to SHD3-97051N for more details.
4 places
How to Order
Specify model number:
SHD30 = Tach/hourmeter w/overspeed
00-00-5489 = backup battery (2 required)
Warranty
A two-year limited warranty on materials and workmanship is given with this Murphy product.
Details are available on request and are packed with each unit.
Find us on the Internet: h ttp:ilw ww.f w m u rp hy.com
In order to consistently bring you the highest quality, fui! featured products, we reserve the right to change our specifications and designs at any time.
FRANK W. MURPHY MANUFACTUFIER P.O. Box 470248; Tupa, Oklahoma 74147; USA tel. (918) 627-3550 fax (91B) 664-6146 e-mail sales@franurphy.com http://www.fwmurphy.com
FRANK W. MURPHY MFR. MURPHY DE MEXICO, S.A. DE C.V. MURPHY SWITCH OF CAUFORNIA
CONTROL SYSTEMS & SERVICES DMSION Bid. Antonio Rodia Cordero 300, Fracción del Aguaje 41343 12th Street West
smurph P.O. Box 1819; Rosenberg, Texas 77471; USA
tel. (281) 342-0297 fax (281) 341-6006
San Luis Potosi, S.L.P.; México 78384
tel. +52-48-206264 fax +52-48-206336
Palmdale, California 93551.1442; USA
tel. (661) 272-4700 fax (661) 947-7570
e-mail sales@fwmurphy.com e-mail ventawnex@mtaphymex.com.mx e-mail salesemerphysWitch.com
http://ywAy.murphyswitch.com
FRANK W. MURPHY, LTD. FRANK W. MURPHY PU., L1D.
Mord Rd.; Lavcrstock, Salisbury SP1 102; U.K. No. 2 Tuas South Street 2, MACQUARRIE CORPORATION
tel. +441722 410055 fax +44 1722 410086 Sprintecs Bk19., n2-01/02 1620 Home Highway;
050,-150 9001 FM 28221 http://mwdwmurphyco.uk tel. +65 863-1398 fax +65 863-0208 tel. +613 9358-5555 fax +61 3 9358-5558
UK-I90 9002 FM 29422 e-mail frensales@fwmurphy.com.sg e-mail murphy@macquarrie.com.au
tel. +33 1 30 762626 fax +33 1 30 763989
Printed in U.S.A.
PD-95145B
tymurphai FRANK W.
Revised 02-97
Catalog Section 55
(00-02-0125)
Pulsation Dampener
PD8100 Series
• Used On Controllers, Instruments and
Recorders to Dampen Pressure Pulsation
• Eliminate Gage Pointer Flutter
• Aids In Providing More Accurate
Pressure Indication
• Decreases Wear On Gage's
Geared Movement
NOT INTENDED FOR USE AS A SHUTOFF VALVE
Description Specifications
The PD8100 Series eliminates pointer flut- See "How to Order" seetion for available Eliminate pointer flutter
ter on pressure indicating SWICHGAGE1 inlet and outlet connections.
like this.
devices which are subject to pulsating PD8183: All wetted parts are Brass.
pressure from reciprocating pumps or Rated to 3,000 psi (20.68 MPa)
compressors. It also allows a close setting [206.80 bar].
of high and low contact points providing
PD8184: All wetted parts are Carbon
for more accurate pressure indication and steel. Rated to 5,000 psi (34.47 MPa)
control of equipment. [344.70 bar].
The PD8100 Series decreases wear on PD8185: All wetted parts are 303 stain-
geared movements and increases the life less steel. Rated to 10,000 psi (68.95
of pressure indicating instruments by
MPa) [689.50 bar].
eliminating excessive gage strain and
PD8190: All wetted parts are 316 stainless
unnecessary movement.
steel. Rated to 10,000 psi (68.95 MPa)
A necessity which quickly pays for itself [689.50 bar]. Meets NACE standard
by protecting any pressure indicating and MR-01-75 for direct exposure to H2S.
control instrument which is subject to Make SWICHGAGE® instruments
pulsation. PD8100 SERIES NOT FOR Operating Temperature: and recorders operate like this.
USE ON OXYGEN OR LIQUID -15 to 400°F (-26 to 204°C)
OXYGEN APPLICATIONS. Shipping Weight (all modeis):
Quality built with a large diameter valve 2 lbs.(0.9 kgs.)
stem wheel for case of adjustment with Shipping Dimensions (all models):
clearly printed operating instructions. 4-3/4 x 4-3/4 x 3-1/4 in. (121 x 121
Machined from 1-3/8 in. (35 mm) hex bar x 83 mm)
stock. A two degree taper on valve and stem
assure positive dampening. Warranty
Available in brass, carbon steel, 303 A two-year limited warranty on materials
stainless steel or 316 stainlesS steel to and workmanship is given with this
meet pressure and environmental require- Murphy product. Details are available on
ments with either 1/2 NPT or 1/4 NPT request and are packed with each unit.
inlet connections.
Service Parts
DESCRIPTION (see drawing—right) PD8183 PD8184 PD8185 PD8190 _ .
A. 1/2 NPT inlet x 1/4 NPT outlet* 65-05-0104 65-05-0210 65-05-0204 65-05-1136 Í( (( (( ( n ) ) )) ))))
1/2 NPT inlet x 1/2 NPT outlet* 65-05-0105 65-05-0212 65-05-0206 65-05-1135
B. Bonnet Fitting 65-05-0099 65-05-0209 65-05-0203 65-05-1139 C E
C. Valve Stem 65-05-0175 65-05-0208 65-05-0202 65-05-1140 o G
D. Packing Nut 65-05-0098 65-05-0211 65-05-0205 65-05-1137
E. Hand Wheel (with 10-32 nut) 55-00-0179 55-00-0179 55-00-0179 55-00-0179
A B
F. Strainer Bushing Assemblyt 55-00-0174 55-00-0173 55-00.0175 55-00-0206
H
G.Molded Packing Gland 00-00-0936 00-00-0936 00-00-0936 00-00-0936
H.'0' Ring Bonnet Seal 00-00-0302 00-00-0302 00-00-0302 00-00-0302
J. Stainless Steel Mesh Filter** 65-05-0214
tProvided only for units with 1/4 NPT ¡niel,
*For 1/4 NPT ¡niel use with strainer bushing assembly.
65-05-0214 65-05-0214 65-05-0214
INLET imi—law
P11111114
hi li il
erlir
i A 1
Art».4r.1 '.......,
I -.41ild
hl
OUTLET
**Provided in units with 1/2 NPT inlet. F J
Dimensions How to Order

PD8185 - 01 - 1/4 x 1/4
Base Nopal
PD8183
PD8184
3-7/8 in.
(99 mm) PD8185
P08190
Service (applies lo PD8184, PD8185 and P08190)

Blank = Standard
01 = Ammonia
3-1/2 in.
(89 mm)
Connection Size
1/4 x 1/4 = 1/4 NPT inlet x 1/4 NPT outlet
1/4 x 1/2 = 1/4 NPT ¡niel x 1/2 NPT outlet
Mounting for the OPLFC Pressure SWICHGAGE® and PD8100 Series
1/2 x 1/2 = 1/2 NPT iniet x 1/2 NPT outlet
The PD8100 Series pulsation dampener is mounted directiy below the OPLFC.
1/2 x 1/4 = 1/2 NPT ¡niel x 1/4 NPT outlet
4-3/4 in.
(121 mm)
diameter
OPLFC
Mounting Shown right, is a typical
Hale
MURPHYMATIC® compressor
panel. This panel features three
1/4 in. (6 mm) diameter
hules (3 pis.) un 5-13/64 in. Pulsation Dampeners and high
(132 mm) B.C.,120° spar',
clocking as shown 5-5/16 in.
pressure flex hoses. The PD's
(135 mm) and hoses are recommended for
1/2 in.
#/—radius use on piston pumps and com-
typical
PD8100 pressors to eliminate pointer
Series 2 in.
Mounting (51 mm) contact flutter and gage wear.
Hale
-01-- 1 in.
(25 mm)
TDX-9106B
Temperature Scanner/Pyrometer Revised 01-98

Catalog Section 10
(00-02-0049)
SWICHGAGE® • Scans 6 Channels

Model TDX6 • Adjustable Trip Points
• "J" or "K" Thermocouples
• Powered by CD Ignition,
24 VDC, or 120 VAC
®
Approved* • Rated for Class I, Division 2,

Group D Hazardous Areas
• Start-up Time Delay
Approved * * • Easy to Read Digital Display
;FIP Pr elEtto
11.1 TFQ TPi rPA t 'rPf * When used with approved ignition.
Contact Murphy for details.
** When used with power reguirements
described below.
Description Specifications
The TDX6 is an advanced design 6-point temperature scanner and Power Requirements (Operating Voltages): 120 VAC or
pyrometer. It continually scans up to six thermocouples and 80-250 VDC, CD ignition or 24 VDC.
sequentially displays the thermocouple number and its reading. Outputs:
Each sensor input has a field settable trip point for alarm, shut- Models TDX6-A and TDX6-C: Six (6) isolated Silicon Controlled
down or control. A read/scan
Rectifier (S.C.R.) outputs; 0.5A 250 VDC; switches on
selector allows the operator to set Easy lo Read
and view each trip point. With the
..-• Digital Display (applies ground) aboye trip point and switches off (removes
selector in the scan mode, a (
Thennocouple
Read
ground) when power is switched off.
Models TDX6-B and TDX6-D: S/A' (6) isolated Field-Effect
"thermocouple read" push button
e Tnp Paint
provides a means to manually Read/Scan Transistor (F. E. outputs; 0.1 A 250 VDC; switches on
toggle through the six channeis Tap Point (applies ground) aboye trip point and switches off (removes
and to lock in on a specific chan- Adjustment ground) below trip point.
nel. Normal scanning will resume Operating Temperature: -4 to 158°F (-20 to 70°C).
approximately three seconds after releasing the push button. All
trip points are continually armed and active during the, scanning Storage Temperature: -40 to 300°F (-40 to 150°C).
process. Case: ABS 1/4 DIN (90 x 90 mm).
Type "J" or "K", grounded or ungrounded thermocouples are Scanning Speed: Complete scan in 30 seconds.
accommodated. Other types are available upon request. Reset Differential: F.E.T. models: Decreases 3 Degrees (°F or °C).
The TDX6 can interface with other Murphy SELECTRONIC1 S.C.R. models: Tum input power off to reset.
TATTLETALP annunciators and Micro-controllers. It is rated for
Display Update Time: Updates temperature every 0.3 seconds.
Class I, Division 2, Group D, hazardous areas* and is available
for operation from CD ignition, 120 VAC, or 24 VDC. Start-up Time Delay: Unit is locked out for 10 seconds after
ignition voltage is sensed.
Applications Ambient Cold Junction Compensation Range:
• Gas Compressor • Process Temperatures 2°F from 32°F to 122°F (1°C from 0°C to 50°C).
Suction/Discharge Temp. • Generators Measurement Range: Monitor Range 0-1999°F or °C (specify °F
• Engine/Compressor Jacket • Pumps or °C in part number).
Water Temperature • Engine Exhaust Temperature Accuracy:
With J-type thermocouple: from 50-150°F(10-66°C) -,3°F(+2°C),
Features from 150-1200°F (66-649°C) ±1.0% of reading.
• Monitors six (6) input sensors With K-type thermocouple: from 400-2000°F (204-1076°C)
• Accepts type "J" or °K' thermocouples grounded or ungrounded
±1.0% of reading.
• Field adjustable trip points
Trip Point Accuracy: ±3°F (±2°C) of reading.
• LCD display in either °F or °C (specify)
• One thermocouple maybe selected for continuous display Trip Point Adjustment Range: 0-1999 Degrees.
• CD ignition, 24 VDC, or 120 VAC powered Open Thermocouple Input: A number 1 appears in the display
• No special training or programming required to the right of the channel number and the trip point operates.
• Scans all 6 sensors in 30 seconds
Dimensions Typical Wiring Diagram
Side View Back View
4-5/8 in. 3-1/2 in.
F"--(117 mm) H(89 mm)—H O INPUT POWER INPUT
JUMPER
® —
. _ j_Load
–• TP1+ •
3-3/4 in. TC 1 < E. ,
- + TC 1 _ • COM • in
LCDT,
(95 mm) PRW TP 2+ •
TC 2 < 1: +-r c 2 INPUT TP 3+ •
MARK II,
S1400,
TC 3 < 1: + Tc 3 COM- • TATTLETALE • etc.
TP 4+ •
4-318 in TC 4 < 1: + TC 4 TP 5+ •
(111 mm) I.— 3 3/4 COM •
6-3/4 in. (95 mm) TC 5 < i: + TC 5 TP 6+ •
(171 mm) COM- •
clearance for plug TC 6 < 1 r TC 6 1
TDX6
Round Hole Mounting (TDXF6)
Mounting Hole
Square Hole Mounting 4-3/4 in. (121 mm) NOTES:
diameter O Remove input jumper when the thermocouple is
3-9/16 in. connected to input.
F"--- (90 mm)—H
T
C)Thermocouple Input
® Power input 120 VAC, 80-250 VDC, CD ignition or 24 VDC,
120° 120° positive or negative ground.
3-9/16 in.
(90 mm) ® Interfaced components must meet area
classification requirements.
® When using the TDX6 with inductive loads, we recommend
installing a suppression diode across al! coils.
1/4 in. (6 mm) dia.
hales (3 places) 120°
How to Order Shipping Weight: 2 lb. (0.91 kg).

To order the TDX6 use the part number designation diagram below.
Shipping Dimensions: 5-1/2 x 9 x 6 in. (140 x 229 x 152 mm).
TDX6 -A-F-J
TDX6 Interface Capabilities
Thermocouple Typo ~/_ Power Source Ra//ng
J — Type J LCDT CD Ign., 120 VAC, 12/24 VDC CI.1, Div.1, Gr. D, Haz. areas"
Modelo = Type S1400 120 VAC or 12/24 VDC CI.I, Div.1, Gr. D, Haz. areas*
TDX6 = Square hole mounting MARK II CD Ignition, pos. or neg. grnd CI.1, Div.2, Gr. D, Haz. amas**
TDXF6 = Round tole mounting Display TATTLETALE° CD Ign., 120 VAC, 12/24 VDC Non-Hazardous areas
F = Fahrenheit PLC's, various non-Murphy annunciators—contact factory.
C = Celsius
*Note: An isolation barrier is needed between the TDX6 and an Annunciator rated
Power Supply/Oofput for Class 1, Division 1, Group D, Hazardous Areas.
A = CD ignition, 80-250 VDC Positive or Negative Ground or **Note: When used with approved ignition. Contact Murphy for details.
120 VAC 50-60 Hz Inputs—S.C.R. Outputset
B = CD ignition, 80-250 VDC Positive or Negative Ground
or 120 VAC 50-60 Hz Inputs—F.E.T. Pulsed Outputstt
C = 24 VDC Inputs—S.C.R. Outputst
Warranty
D = 24 VDC Inputs—F.E.T. Pulsed 0utputstt
A two-year limited warranty on materials and workmanship is
t For use with electromechanical TATTLETALP annunciators.
given with this Murphy product. Details are available on request
ttFor use with SELECTRONIr or similar solld-state annunciators.
and are packed with each unit.
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specffications and designs at any time.
. phi§
■ Frank W. Murphy, Ltd.
Church Rd.; Laverstock, Salisbury SP1 10Z; U.K.
■ Murphy de México, S.A. de C.V.
Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
Since 1939 mr.. tel. +44 1722 410055 fax +441722 410088 tlx 477088 San Luis Potosí, S.L.P.; México 78384
■ Frank W. Murphy Manufacturar e-mail sales@fwmurphy.co.uk tel. +52-48-206264 fax +52-48-206336
P.O. Box 470248; Tulsa, Oklahoma 74147; USA ■ Frank W. Murphy Pta., Ltd. e-mail murmexsl@sanluis.podernet.com.mx
tel. (918) 627-3550 fax (918) 664-6146 No. 2 Tuas South Street 2, Sprintecs Bldg., #02-01/02 ■ Murphy Switch of California
e-mail sales@fwmurphy.com Singapore 638042 P.O. Box 900788; Palmdale, California 93590; USA
tel. +65 863-1398 fax +65 863-0208 tel. (805) 272-4700 fax (805) 947-7570
■ Frank W. Murphy Southern [Avistan
e-mail fwmsales@fwmurphy.com.sg e-mail sales@murphyswitch.com
P.O. Box 1819; Rosenberg, Texas 77471; USA
tel. (281) 342-0297 fax (281) 341-6006 ■ Murphek Pty., Ltd. ■ Frank W. Murphy France
e-mail murphysd@intertex.net 1620 Hume Highway; Campbellfield, Vic 3061; Australia tel. +33 1 30 762626 fax +33 1 30 763989
tel. +61 3 9358-5555 fax +61 3 9358-5558
Printed in U.S.A. e-mail murphy@macquarrie.com.au 0591127
VS-94092B
"FRANKly ®
-405-mur h PMFR9
Revised 10-99
Catalog Section 20
(00-02-0077)
Shock and Vibration Control Switch

VS94 Model
• NEMA 4, 4X Enclosure (CSA Types 4 & 12)
• Protects Your Equipment from Excessive
Shock or Vibration
• Fine Adjustment to Precisely Select the
Degree of Sensitivity
• Reset from a Remote Location (Optional)
• Time Delay to Override Trip Operation
at Start-up (Optional)
• Space Heater to Prevent Moisture
Condensation Inside the Unit (Optional)
Description Applications • Remote Reset (Optional)

VS94 Series is an electro-mechanical device Applications for the VS94 include all sta- • Adjustable Start-up Time Delay (Optional)
designed to protect equipment from damag- tionary types of machinery or equipment
• Space Heater Circuit to Prevent Housing
ing shock or vibration. This sensitive mech- where excessive shock/vibration can be
Moisture Condensation (Optional)
anism can detect excessive shock or vibra- damaging or poses a threat to normal opera-
• Two (2) versatile SPDT snap-switches
tion and shutdown the equipment before fur- tions such as in:
rated up to 480 VAC.
ther damage occurs. A set of contacts is held • Cooling fans
in a latched position through a magnetic • Engines
latch mechanism. As the level of shock or Options
• Pump jacks
vibration increases an inedia mass exerts Remote Reset
• Compressors
force against the latch arm and forces it This option of the VS94 includes a built-in
• Pumps electric solenoid which allows reset of
away from the magnetic latch causing the
• Rotating and Reciprocating Machinery tripped unit from a remote location.
latch arm to separate and to operate the con-
tacts. Sensitivity is obtained by adjusting the Available for 115 VAC or 24 VDC.
Features
amount of air gap between the magnet and Time Delay
• Electromechanical Design
latch arm plate. Overrides trip operation on start-up.
• Detects Shock or Vibration in
The VS94 Series is housed in a NEMA 4/4X The time delay option is field-adjustable
Three Planes of Motion
glass filled polyester enclosure and has a from 5 seconds up to 6-1/2 minutes with an
• NEMA 4/4X (CSA types 4 and 12)
base mount. It is for applications in non-haz- easy-to-adjust 20-turn potentiometer.
Weather-proof Enclosure
ardous locations. Available for 115 VAC or 24 VDC.
• Reliable Magnetic Latch Feature
VS94 models are rated up to 480 VAC. • Micro Fine, Easy-to-Adjust Space Heater
(See the How to Order section on back page Sensitivity Adjustment This optional circuit prevents moisture con-
for models and options available.) densation inside the VS94 housing.
• Manual Reset (Standard)
Specifications Dimensions
Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; 1P66;
CSA types 4 and 12. VS94 Series Models
Conduit Fitting: 3/4 NPT conduit fitting connection.
6-29/32 in.
Normal Operating Ambient Temperature: (176 mm)
O to 140°F (-18 to 60°C).
Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A
resistive, lA inductive, up to 30 VDC. Manual
7-9/64 in. Reset
Range adjustment: O - 7 G's; O - 100 Hz /0.100 in. displacement. (181 mm) Push-button
Space Heater (optional):
Option Operating Current
H15 .023 A @ 115 VAC 6-1/2 in.
H23 .011 A @ 230 VAC (165 mm)
H24 .12 A @ 24 VDC
Remote Reset (optional):
Option Operating Current
R15 .17 A @ 115 VAC
R24 .36 A @ 24 VDC Mounting slot
Time Delay (optional):
5/16 x 9/16 in. L 4 in.
Option Operating Current Standby Current
(8 x 14 mm) r (102 mm)—
4-places.
T15 .360 A @ 115 VAC .01 A @ 115 VAC
T24 1.15 A @ 24 VDC .01 A @ 24 VDC
Time Delay/Remote Reset: Adjustable 20-turn potentiometer from
5 seconds to 6-1/2 minutes (15 seconds per turn approximately). 4-5/8 in.
(118 mm)
Shipping Weight: 4.35 lb. ( 2 kg.)
Shipping Dimensions: 9 x 8 x 4-11/16 in. (229 x 203 x 119 mm)
3/4 NPT
1-5/8 in. conduit fitting
(41 mm)
How to Order
1
To order your VS94 model use the diagram below.
4 in.
(102 mm
VS94 -
6-1/2 in.
(165 mm)
Space Heater Remote Reset
Blank = No Space Heater Blank = No Remote Reset
H15 = 115 YAC R15 =115 VAC
H23 = 230 VAC R24 = 24 VDC
Warranty
H24 = 24 VDC
A two-year limited warranty on materials and workmanship is
Time Delay given with this Murphy product. Details are available on request
(Includes remate reset feature) and are packed with each unit.
Blank = No Time Delay
T15 = 115 VAC
TU = 24 VDC
■ Frank W. Murphy, Ltd. ■ Murphy de México, S.A. de C.V.
Tliyariírphii
Since 1939 14"•
Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.
tel. +44 1722 410055 fax +44 1722 410088
Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
San Luis Potosi, S.L.P.; México 78384
■ Frank W. Murphy Matuteen:ter e-mail sales@fwmurphy.co.uk tel. +52-48-206264 fax +52-48-206336
P.O. Box 470248; Tulsa, Oklahoma 74147; USA ■ Frank W. Murphy Pte., Ltd. e -mail murmexsl@sanluis.podernet.com.mx
tel. (918) 627-3550 fax (918) 664-6146 No. 2 Tuas South Street 2, Sprintecs Bldg., #02-01/02 ■ Murphy Switch of California
e-mail sales@fwmurphy.com Singapore 638042 P.O. Box 900788; Palmdale, California 93590; USA
tel. +65 863-1398 fax +65 863-0208 tel. (805) 272-4700 fax (805) 947-7570
■ Frank W. Murphy Southem Division
e-mail fwmsales@fwmurphy.com.sg e -mail sales@murphyswitch.com
P.O. Box 1819; Rosenberg, Texas 77471; USA
tel. (281) 342-0297 fax (281) 341-6006 ■ Murphek Pty., Ltd. ■ Frank W. Murphy France
e-mail sales@fwmurphy.com 1620 Hume Highway; Campbellfield, Vic 3061; Australia tel. +33 1 30 762626 fax +33 1 30 763989
tel. +61 3 9358-5555 fax +61 3 9358-5558
Printed in U.S.A._ e -mail murphy@macquarrie.com.au
L12-9102B
Revised 04-00
Catalog Section 15
(00-02-0060)
Level Controls for Scrubbers

L1200 Series Patents 3970099, 4505288, 4573489
Model L1200
Float Operated Electric CE** • BUOYGLAS' Float Operates to 0.5 Specific Gravity
• Stainless Steel Models Meet NACE Requirements
and Carry Canadian Registration Numbers
• Models Rated for 2000 psi (13.8 MPa) [138 bar] Vessels
• Models Listed for Class I, Division 1 Locations
Model L1200N L1100 and L1200 Series Level Switches
Float Operated Pneumatic These float operated level switches are available in electric and pneumatic models.
They are primarily designed for high level applications but models are available for
low level. Electric models are listed for Class I, Division 1, Groups C & D hazardous
locations. Models are available in all stainless steel to NACE standard MR-01-75 for
direct exposure to H2S service. These level switches have screw-in connections for
direct installation or an optional externa] float chamber is available for the L1200
series high pressure versions. The high pressure versions of both L1100 and L1200
series are rated for 2000 psi (13,8 MPa) [138 bar] operating pressure. See the
specifications sections of this bulletin for further details.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
Model L1200NDVOR L1200NDVOR series carry Canadian Registration Number 0F1476.2.
Float Operated Pneumatic with Dump Valve
Application: L1100 and L1200 Series
Operator, Pressure Regulator and Gage
Designed primarily for gas compressor scrubber leva Low pressure models can be
used anywhere level switching of a non-pressurized vessel is required. Electric models
are typically used for high level shutdown of the engine or electric motor, while
pneumatic models operate vessel dump valves such as Murphy DV-series. Models
designed for low level switching have been used for fuel, lube oil, hydraulic oil, etc.
DV Series Dump Valves

The DV2100, DV875 and DV850 are pneumatically
controlled dump valves. These valves open and close
automatically by pneumatic control from an L1200NDVO or
similar dump valve operator. Diaphragm actuated, the DV series
valves operate at 30-70 psi (207-483 kPa) [2.07-4.83 bar] with up DV875
to 2000 psi (13.7 MPa) [137 bar] vessel pressure. A pop up button Dump
indicates valve open/closed. Valve
Model L1200NDVO Primarily engineered for compressor scrubbers, there valves can be applied to any liquids
Float Operated Pneumatic with Dump Valve dumping job that is compatible with the valves materials, pressure limit and flow rates.
Operator NOTE: All stainless steel versions of DV850, DV875, and DV2100 series carry
Canadian Registration Number 0C1476.2.
SLS99 MURPHYlVlATIC* Scrubber System

A complete MURPHYMATIC® system for automatic level control of condensate in
scrubbers, including periodic dumping and high level shutdown, is available as a
complete package from Murphy. All wetted metal parís are electroless nickel plated or
stainless steel. The SLS99A scrubber system includes:
(1) DV850 MURPHY NU-MATICTm Dump Valve*
*DV875 and DV2100 dump valves are also available for this system (see page 4). (1) L1200NDVOR MURPHY NU-MATICTm Dump Valve Operator which
See page 2 for system operados. includes a Filter/Regulator and MURPHYGAGE1
* *Products covered by this bulletin comply with EMC Council directive
89/336/EEC regarding electromagnetic compatibility except as noted. (1) L1200 High Level Shutdown switch
Specifications L1100 L1111 L1150 L1200 L1250 L1200N L1200NDVO L1200NDVOR
Body
• Standard: Electroless Nickel placed steel iii A igA /A II ' N8 18 II 8 El
• Optional: 316 Stainless Steelt EA EA EA .8 II A II 8 .8 UA

Pressure Rating
• 15 psi (103 kPa) [1.03 bar] Polyethylene Float
• 1500 psi (10,3 MPa) [103.42 bar] Stainless Float : E
• 2000 psi (13.8 MPa) [138 bar] BU0YGLASTM' Float
Temperature Rating
• Standard: -20/175°F (-29/79°C)
• Standard: -20/300°F (-29/149°C)
• Optional: -20/400°F (-29/204°C)*
Specific Gravity
• Standard: 0.5 with BUOYGLASTM float
• Optional: 0.65 with 304 Stainless Steelt
• Standard 0.73 Polyethylene Float
Electrical
• Standard SPDT: 5 A e 125/480 VAC (see p. 3 for full ratings)
• Optional DPDT: 10 A @ 250 VAC (see p. 3 for full ratings)
Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm)
0-Rings: Viton E
Valve: Two-way snap-action vent type
• 1/8 in. (3 mm) orifice wNiton "A" seat
• 1/8 NPT inlet; 1/4 NPT outlet
• 30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure
Dump Valve Operator: Operates Murphy DV Series
dump valves or similar.
Pressure Regulator/Filter and Murphy 20BPG:
0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge. U
Maximum input 300 psi (2.07 MPa) [20.68 bar].
Operation:
H=For high level, L=For low fevel
H L H H H H H H
A =1.112 NPT =2 NPT tMeets NACE standard MR-01-75 for direct exposur to H2S service. * Not available with DPDT snap-switch.
SLS99 Scrubber System

Patent No. 4505288 If for any reason the condensate continues to rise beyond
• High Level Shutdown • normal dump levels, the L1200 operates the alarm and/or shuts
• High Level Dump Valve • down the equipment,
• High Level Dump Valve Operator • The MURPHYGAGE® and Filter/Regulator on the L1200NDVOR
helps keep the control pressure clean and dry. It also allows
operator to adjust pressure to recommended levet.

L1200 (with snap-switch) 300 psi (2.07 MPa)
Minimum control
pressure 30 psi [20.70 bar]
High Liquid Level MURPHY NU-MATICT" (207 kPa) [2.07 bar]
Shutdown Switch MURPHY NU-MATICT" Dump Valve Operator Electrical
(L1200) Dump Valve (L1200NDVOR) Conduit
(DV850/875/2100) Patent No. 3970099
Patent No. 3970099 L1200NDVOR
Patent Pending Dump Valve Operator,
Filter/Regulator
with MURPHYGAGE•
SLS99 System Operation
As condensate rises in the scrubber, the float on the L1200NDVOR Minimum control pressure
rises and trips it's pneumatic valve. The valve opens allowing 30 psi (207 kPa) [2.07 bar]
pressure to enter the dump valve pilot chamber. Once the

pressure enters the pilot chamber it forces the diaphragm and MURPHY NU-MATIC•
Dump Valve: DVI350,
valve stem forward thus opening the valve seat and releasing DV875, or DV2100
condensate through the valve stem and out the drain. As the Union
condensate level drops, the L1200N pneumatic valve closes to
shut off the pressure to the dump valve causing it to close. --P-Condensate Out
Dimensions Accessories
11 in.
L1100 (279 mm) Adaptor Bushing 55050617
3-1/2 in.
and (89 mm) for DV850 and DV875
2.1/16 in
L1200 (52 mm)
T 1-1/16 in
2-3/16 in. See (27 mm)
(56 mm) Note 2
Note 1: 1 NPT
L1100: 1-1/2 NPT j_ _L
L1200: 2 NPT
Note 2: 1-9/16 (40 mm) 1/2 NPT See Float travel between Operate
Note 1 and Reset= 0.25 in. (6 mm).
SF option: Switch operates on Rising Level
1.1100: 1-1/2 (38 mm) 3-5/8 in. 2 NPT
w/ float at horizontal centedine
L1200: 1-3/4 (44 mm) (92 mm) 1110.25 in. (6 mm). Material: 2-1/2 Hex bar stock C.R.S
L1111 11-5/16 in. Float Chamber 15050697

(287 mm)
2 NPT
2-3/16 in. See

(56 mm) Note 3-1/2 in.
(89 mm)
1 1-lex
1/2 NPT Float travel between Operate

and Reset= 0.25 in. (6 mm).
Note: 1-9/16 (40 mm) Switch operates en Rising Level Material: Casi Steel, WCB
SF option: 1-1/2 (38 mm) 3-5/8 in. w/ float at horizontal centedine Canadian Registration Number. 0H1476.2
(92 mm) a0.25 in. (6 mm).
Operating Pressure 2000 psi (13.8 MPa) (138 bar)
Operating Temperature: 400°F (204°C)
L1150 Typical L1200/L1200N Float Chamber Installation
and
L1250
Tank
S
Note 1: L1150: 1-1/2 NPT 1/2 NPT N ote 1 Float travel between operate
L1250: 2 NPT and reset= 0.75 in. (19 mm).
3-5/8 in. Switch operates on Rising level w/ float at
Note 2: L1150: 1-1/2 in. (38 mm) (92 mm) horizontal centedine 50.25 in. (6 mm).
L1250: 2 in. (51 mm)
Pressure L1200N, L1200NDVO Weld Collar 15050375

Regulator
(use with L1200 only)
with 20BPG
Pressure Gage New Dump Yervo
and L1200NDVOR
Operator Assembly
p/n 15010216
with Dump
Valve Operator,
Pressure Regulator
Old Round Dump Valve
W embly
and Gage
4-1/2 in
(114 mm) Material: ASTM A105-2
3-5/8 in. (92 mm) -.• 5 in. (127 mm.) minimum UNS K03504
clearance is required for
314 Hex float movement Typical L1200 Weld Collar Insta lation
(Sea Note)
2-3/16 in. Operating Pressure:

—1-9/16 in.
(56 mm)
(40 mm) 2000 psi (13.8 MPa) (138 bar]
SF option= Operating Temperature:
1-3/4 In.
2 11-1/2 NPT (44 mm) 400°F (204°C)
3-1/2 )n. (89 mm)
F= 3-3/4 In. (95 mm)
[—11 in. (279 mm) SF option= 11-1/4 in. (286 mm)
Note: For use only with Old Round Dump Valve Operator Assembly (15000940),
Wiring DPDT (snap-switch) Float Shaft Extension 15000892

Green Grd. Connection ///////// J 10-32 UNF
Bleck N.O. o 1_ whne /,
SPDT (snap-switch) COM. I
Bleck N.O. o
Red N.C.
Green Grd. Connection
_L White COM.
Red N.C. 0--f
Blue N.C.
Oranee N.C.
o
0 Yellow COM. 10-32 NF
JVIll Il I
I
1 3/8 in 3/8 In
o (35 mm) (10 mm)
Switch Ratlng: 5 A 125-250- 480 VAC Switch Rating: 10 A 'II 125-250 VAC Material: AISI 304, UNS-S30400
1/2 A 41 125 VDC 1/2 A /8 125 VDC
1/4 A /8 250 VDC 1/4 A ID 250 VDC NOTE: The extension is used with the L1100 and L1200 only. One extension
2A @ 6-30 VDC Resistive 10 A (I 6-24 VDC is supplied with each unit. Use of additional extensions is not recommended
1A @ 6-30 VDC inductive InductivetResistive as they reduce the ability of the unit to opereta for the stated specilic gravity.
How to Order
L1100 and L1200 Series Replacement Parts (order by part number designation)
Build a complete model number using the diagram below. See L1100/L1200
,example. See Specifications Chad on page 2 for standard and 15000893: BUOYGLASTM float
Jptional features. 15000894: Stainless Steel float for L1200
15000937: Stainless Steel float for L1100
Example model number 15000124: SPDT snap-switch assembly
L1100 - 15010213: L1100 counter balance assembly
15010214: L1200 counter balance assembly
Options L1200N
D = DPDT 15050420: Cam spring return
K = KALREZ Seals 15050421: Cam
SF = Stainless Steel Float 15000893: BUOYGLASTM float
400 = 400°F (204°C) Service** 15000894: Stainless steel float for L1200N
15050453: Valve stem
15010189: Counter balance assembly
L1200NDVO and L1200NDVOR
Base Models
55050621: Regulator only
L1100* L1100SS 05706499: 20BPG-D-75 psi (0-517 kPa) [0-5.17 bar]
L1111 L1111SS 15010216: DVOA assembly (New rectangular style)
L1150 L1150SS 15000940: DVO assembly (Old round style)
L1200* Ll 200SS* 00003341: Filter for regulator
L1250 L1250SS 00003340: Regulator diaphragm kit
L1200N* Ll 20ONSS*
L1200NDV0* L1200NSSDV0* Shipping Weights
L1200NDVOR* L1200NSSDVOR* L1100: 61b. (2.7 kg).
L1111: 5 lb. 11 oz. (2.5 kg).
*Stainless steel models carry Canadian Registration Number 0F1476.2. L1150: 5 lb. 4 oz. (2.3 kg).
**Not available with DPDT snap-switch. L1200: 6 lb. 6 oz. (2.8 kg).
L1250: 61b. 6 oz. (2.8 kg).
L1200N: 51b. 5 oz. (2.4 kg).
L1200NDVO: 51b. 14 oz. (2.6 kg).
Complete SLS99 Systems
L1200NDVOR: 61b, 10 oz. (3 kg).
Specify
SLS99: 191b. 6 oz. (8.7 kg).
SLS99A: (uses DV850) with 1 NPT
SLS99B: (uses DV2100) with 2 NPT Shipping Dimensions
SLS99C: (uses DV875) with 1 NPT L1100: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
L1111: 14 x 5 x 3-1/2 in.(356 x 127 x 89 mm).
Accessories (order by part number designation) L1150: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
15050375: Weld collar
L1200: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
15000892: Float shaft extension L1250: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
55050617: DV850 adaptor bushing 2 NPT-M to 1 NPT-F L1200N: 14 x 5 x 3-1/2 in. (356 x 127 x 89 mm).
15050697: External Float Chamber (Canadian Registration L1200NDVO: 14 x 5 x 3-V2 in. (356x 127 x 89 mm).
Number OH1476.2) L1150NDVOR: 10 x 9-1/2 x 6 in. (254 x 241 x 152 mm).
SLS99: 15 x 15 x 12 in, (381 x 381 x 305 mm).
Warranty
A two-year limited warranty on materials and workmanship
is given with this Murphy product. Details are available on
request and are packed with each unit.
FRANK W. MURPHY MANUFACTURER P.O. Box 470248; Tuba, Oklahoma 74147; USA tel. (918) 627.3550 fax (918) 6646146 e-mail sales@fwmurphy.com http://strww.funnurphy.com
FRANK W. MURPHY MFR. MURPHY DE MEXICO, S.A. DE C.V. MURPHY SWITCH OF CALIFORNIA
CONTROL SYSTEMS & SERVICES DIVISION Bhal. Antonio Rodia Cordero 300, Fracción del Aguaje 41343 12th Street West
P.O. Box 1819; Rosenberg, Texas 71471; USA San 61Potosi, S.L.P.; México 78384 Palmdale, California 93551.1442; USA
tel. (281) 342-0297 fax (281) 341-6006 tel. +52-48-206264 fax +52-48-206336 tel. (661) 272.4700 fax (661) 947-7570
e-mail sales@fwmurphy.com e-mail ventasmex@murphyrnex.com.mx e-mail sales@murphyswitch.com
http://www.murphyswitch.com
Church Rd.; Laverstock, Salisbury SP1 10Z; U.K. No. 2 Tuas South Street 2, MACQUARRIE CORPORATION
tel. +441722 410055 fax +441722 4113088 Sprintecs Bldg., n2-01/02 1620 Hume Highway;
e-mail sales@fwmurphy.co.uk Singapore 638042 Carimbellfield, Vic 3061; Australia
USA-150 9001 FM 28221 http://www.fasnurphy.co.uk tel. +65 863.1398 fax +65 863-0208 tel, +61 3 9358-5555 fax +61 3 9358-5558
UK-150 9002 FM 29422
e-man femsates@hvnurphy.com.sg e-mail murphy@maequarrie.com.au
tel. +33 1 30 762626 fax +33 1 30 763989
Printed in U.S.A. 0191096
TYPE P-50 AND P-125 AND P-225 INDUSTRIAL
MULTI-SEAT REGULATOR
:1'
J-31
P- 21 0-17
J-4
G-15
G-I9
11111( 0-10 o
J-30
J-24 G- 61 o
J-5 J-18
G-20
J-8 0-18
Stscig 14.. Pert Ne, Qi'urip!•n

5411 P-1.0A Body
5412 P•1-DC Body
5413 P.1.00 Body
5418 P•2 Bonnet, for "T" Typo/ Adjusting Screw same as J.2
5419 P-2.41 Bonnet, for Slotted Typo/ Adjusting Screw same as J-2-Á
5424 P•3 Bock Cap
4528 1.4 Adjusting Screw Assembly
5259 1.5 Spring Button
5263 1.7-A Compression Spring for 30 lb. Pressure
5264 J-7.! 25 Compression Spring for 125 Ib. Pressure
5267 1.8 Diaphragm Mate
5268 1-9 Diaphrogen
5140 G-10 Yak*
5269 J-11 Diaphragrn Gasket
5145 G.12 Bonnet Screw
5155 G-13 Yoke Gasket .
5215 G-61 Filter Screen
5158 G.15 Nozzle with 5/64" Orifico,
4521 G.17 Seot Block with White Seats
4522 G-17 Seas Block with Block Sea,:
4524 G-17 Seat Block with arar Seats
5270 J-18 Rear Spring, for 500 Ib. or less Inlet Primar,
5177 G-1 8 Rear Spring, for over 500 lb. Inlet Pressure
5181 G-19 Yoke Camping Screw
5182 G-20 Yoke Guide
5429 P.21 Bock Cap Gasket
5272 J-24 Diophrogm Plato/ Nut
5273 1-30 Slot Typo/ Adjusting Screw
5274 1.31 Protention Cap for Slot Adjusting Screw
5400 OR•75 P-225 Bonnet Spring
MODERN ENGINEERING CO., INC. St. Louis, Mo. 63103

Ll;
ENGINE ERING OIL LEVEL CONTROLLER
BULLET1N LC
091583
DESIGN CHARACTERISTICS
NO SAFETY SWITCH.
OIL CONTROL VALVE

• Operates at inlet oil statIc head pressure of
1 to 15 fest
• HIgh Pressure Model avallabie for 5 to 70 pat.
• 011 Inlet Housing can be rotated 360°.
• Mechanlsm fully removeable without draining oil.
• 1/2" NPT Inlet, W NPT Outlet
• Visual 1/4" thlck Pyrex Sight Glass
MODEL LC
EQUIPMENT SPECIFICATIONS
ENGINE MODE- NO. ENGINE

MODEL NO.
LC-11 OIL CONTROLLER with ADAPTER for

LC OIL CONTROLLER less MGT. BRKT.
LUBRICATOR.
LC-1 OIL CONTROLLER with ADAPTER for CLARK
LC-14 OIL CONTROLLER with ADAPTER for WHITE
MA & CFA.
COMPRESSOR.
HMB & TMP.
INGERSOLL RANO XVG & PVG.
RA, HRA, HBA, HCA, HLA, & TLA.
COOPER-BESSEMER GMV 275.
INGERSOLL-RAND SVG,
WAUKESHA VHP 6 and 12 CYLINDER GAS
LC-5 OIL CONTROLLER with ADAPTER for OR DIESEL SERVICE ENGINES.
INGERSOLL-RAND KVG & KVS.
LC-6 OIL CONTROLLER with ADAPTER for WAUKESHA VHP "L" SERIES GAS ENGINES
COOPER-BESSEMER GMW. WITH SLOW FLOW METER MOUNTED BESIDE
OIL CONTROLLER with ADAPTER for THE OIL CONTROLLER.
LC-7
COOPER-BESSEMER GMV. LC-19 OIL CONTROLLER with ADAPTER for
OIL CONTROLLER with ADAPTER for INGERSOLL-RAND ROTARY.
LC-8
COOPER-BESSEMER GMX. LC-37 OIL CONTROLLER with ADAPTER for
OIL CONTROLLER with UNIVERSAL WAUKESHAVHP 16 CYLINDER GAS or DIESEL
LC-9
ADAPTER. SERVICE ENGINES.
OPTIONS
FIRE SAFE Add FS to model number. HIGH PRESSURE — Add HP to mode' number.
HOSE KIT — Add K to model number. EXAMPLE: LC -3-FS-HP-K
1
IJcnr-riN
011 Va 411. a•
•••
.1.
= ••I
mil ..,
«o V.»
••■ •■■•
MB
MI.
•••,
•■•
1.1
••
MB,
MI• PNEUMATIC LOW OIL LEVEL SWITCH
E N G 1 N E ERING
BULLET1N PS/E5
110164
DESIGN
CHARACTERISTICS
• Low Level Pneumatic Switch opens when the oil
level drops Va" below the center of the gauge
glass.
• High Level Pneumatic Switch apena when the oil

level risas 3/4" aboye the center of the gauge
glass.
• Maximum iniet pressure la 100 PSI
• 1/4" Thick Pyrex Visual Gauge
• The Model PS Switches utiliza Me same com-

ponent parts as are usad In the LCP Oil Level
Controller
MODEL PS-9
EQUIPMENT SPECIFICATIONS
MODE!. NO. DESCRIPTION
PS- 9 Low Level Switch with Universal Mounting Bracket
PS-11 Low Level Switch with Adapter for Lubricator
119-9 High Level Switch with Universal Mounting laracket

IN-LUBRICATOR OIL LEVEL CONTROLLER
WITH SAFETY SWITCH
muno un
FOR tiOle3
LINCOLN ST. LOUIS (McCORD) OR MEGA

LUBRICATORS
MODEL 5071.
Model 507L fits the extra pump pocket on Lncoin
St. Louis (McCord) and Mega force-leed
Iubncators.
The 507L autcrraticaíly adds the needed amount
of lubricant te maintain the leve) 11/4" below the
cover plata of the lubricator. The Safety Switch will
send an electrical signai when the oil suppiy from
the outside source is
SPECIFICAT1ONS
SWITCH RATING - 2 arnp, 30 V ac or dc.

INLET PRESSURE - 1' to 14' head of oil.
INLET HOSE
CONNECTION • 1/2" NPT.
5071.
ELECTRICAL
CONNECTION • 1/2" NPT Conduit Connection.
18 Gauge Wire, 36" Long.
VALVE MATERIAL - Suna N (Soft Seat).

OPTIONAL Viton (Soft
Seat) (for use with
synthetic oil. Order
Model
SHIPPING WEIGHT - 15 Oz.
FLOW RATE - 2' head at 32° F SAE 30.
1.1413 Gallons per Hour.
HIGH PRESSURE MODEL 507L-HP

Specifications as aboye except
INLET PRESSURE - 5 psi to 60 psi.
1 FLOW RATE « 5 psi at 32° F SAE 30
6425 Gallons per Hour.
Model 507L-V -HP avaiiabie.
NO CUSTOMER REPLACEMENT PARTS LUSRICATOR BOX WITH 5071 INSTALLED

Page 1 of 4 TD-1277
3-12-79
REV.11-12-86
SETTING AND GROUTING INSTRUCTIONS-ROTATING MACHINERY

WITH SOLE PLATES OR FABRICATED BASES
I SCOPE:
This standard covers the procedures for setting and grouting of skid
mounted machinery of fabricated bases which have self-contained leveling
screws.
II PREPARATION OF FOUNDATION:
A. Check foundation bolts for proper location before and after bouring
foundation. See certified foundation drawings furnished by Ajax
for proper location. The foundation bolts should be of the type
shown on the foundation drawing furnished by Ajax.
B. The foundation contractor should have prepared the area which will
be covered by grout by chipping from these areas all laitance and
oil-soaked or damaged concrete. If he has omitted this operation,
remove from the areas where the grout must bond enough of the
surface of the foundation approx. 1/4" to 1/2" to lay grout on bare
uncontaminated, homogenous concrete.
C. Set leveling plates in level position on the foundation under the

leveling screw locations.
III PREPARATION OF SKID BASE:
A. All concrete to cure for at least 15 days before grouting the

uni t.
The bottom of the skid flanges or unit and cooler must be wiped
clean with methyl-Ethyl-Keystone or equivalant (lacquer thinner) .
Caution These solvents are extremely volatile and proper fire
prWriTions should be taken by keeping the volatile area well
ventilated and free of any type of spark. The bottom of the skid
must be free of paint and any other foreign matter.
C. Apply any paste wax to Jackscrews to prevent adhereing to the

grout.
D. Set unit skid over foundation bolts with leveling screws resting on
leveling plates. Repeat procedure for side mounted cooler if this
unit has a side mounted cooler foundation mounted. Rough leveling
may be done with a machinists level. However, by properly
torqueing each leveling screw to a designated torque valve a more
precise leveling and controlling of web deflection can be
accomplished.
Page 2 of 4 TD-1277
3-12-79
REV.11-12-86

E. Install cooler belts, idler and make all interconnecting pipe runs
making sure cooler is level in relation to the unit.
Provisions need to be made to orain compartments in skid by

providing drainage slots Between skid and grout so liquids cannot
collect in skid.
IV GROUTING INSTRUCTIONS:
A Grout should have the following characteristics:
1. A consistency which will allow proper placement.

2. High bonding strength.
3. High dimensional stability.
4. Strength to transmit static and dynamic forces from unit -
to foundation.
B. Grout may be of the conventional type, or may be "Ceilcote: or

other epoxy resin type. The surfaces to which it must bond should
be wet in the case of conventional grout, and absolutely dry in the
case of "Ceilcote" or the other epoxy resin.
1. If epoxy resin or premixed conventional type grout is

used, it should be mixed according to instructions on the
container.
2. If a cement mix is to be prepared, (conventional grout)

proportions should be as follows:
a. 1 part cement, by volume

b. 1-1/2 parts sand, by volume
c. 5-1/2 to 7 gallons water per 100 pounds of cement
depending on moisture content of the sand.
C. Prepare the leveling screws by applying a paste type wax to the

portion of threads which extend into grouted area.
D. Make sure that the foundation bolts are torqued to a max. of 50

ft./lbs. before pouring during curing of grout.
Page 3 of 4 TD-1277
3-12-79
REV.11-12-86

•
E. The final level of the grout should be approximately up to the

flange thickness of the skid when using an epoxy type grout. In
case of a fabricted skid base, all skid members that are flush
with bottom of skid should be grouted.
F. Grout skid base using procedgres suitable to the application or

unit involved. Care must be taken to provide adequate forms to
maintain grout. Remove any excess grout before it has completely
set.
G. Grouting should not be attempted at tempertures below 50 degrees F.
H. The area to be grouted must be clean an free of dust and make sure
bottom of skid is clean.
I. Provisions need to be made to drain conpartments in the skid by

providing drainage slots between skid and grout so liquids cannot
accumulate in the skid.
CAUTION:
"Ceilcote" and other eposcy resin type grouting materials may

present cetain health hazards. The grouting manufacturer's
handling instructions should be strictly followed.
VII FINAL GROUTING INSTRUCTIONS:
A. After grout has set sufficiently to carry the weight of the unit,
relieve the load on all leveling screws. This is essential to
insure that the unit is being supported only by the grout, not by
the screws.
B.. Properly tighten foundation bolts after grout has sufficiently

cured by using table I for proper torque values.
Page 4 of 4 TD-1277
3-12-79
REV.11-12-86

TABLE I TORQUE VALUES
THREAD DIA. INCHES THREADS PER-INCH TORQUE FT-LBS
5/8 11 50
18 60
3/4 10 95
16 105
7/8 9 150
14 170
1 8 225
12 245
14 260
1-1/8 7 320
12 370
1-1/4 7 450
12 520
1-3/8 6 590
12 700
1-1/2 6 800
12 930
1-5/8 8 1130
3-11-80
RECOMMENDED STARTING PROCEDURE FOR AJAX COMPRESSORS LESS BY-PASS PIPING
TD 1292
1. Open adj. plugs or pockets to full open on both cylinders
2. CLOSE SUCTION BLOCK VALVE.
3. Leave discharge plug valve open only if check valve is installed

immediately clown stream of cooler which we feel is a must.
4. Open manual drain valve on suction and interstage separators and

1" drain or manual blowdown valve on final discharge of compressor.
5 After ample warm up (minimum 20-30 minutes at minimum speed), close

manual drain valves on separator and leave manual blowdown open and
crack open suction block valve to purge system of any air.
6. With suction block valve cracked open close manual blowdown valve
and gradually open suction block valve to give proper suction pressure
to curve requirements and bring unit up to speed.
7. Adjust clearancing to curvé so not to overload unit or to create

excessive rod loading.
T0-1344
3-15-86
REY: 8-12-86
Page 1 of 5
PREVENTATIVE MAINTENANCE MANUAL
The following maintenance schedule is to be used as a guide line in setting up

a maintenance schedule on your machine. We feel the best maintenance program
is a preventative type which will help detect the beginning of problems before
failure occurs.
This schedule is similar to the one sone of our customers use in their
preventative maintenance program and appears to have given then good results
• in preventing costly breakdowns.
We are in no way saying the Aiax package will not give long trouble free
continous service without such a maintenance program , but common sense rules
that the more preventative maintenance is done the iess chance of an unexpected
failure to occur and the longer the unit will run trouble free.
TD-1344
Page 2 of 5
SCHEDULE "A"
(WEEKLY)
1. Check lubricator oil level.

2. Check crankcase oil level.
3. Check each lubricator punp to make sure each pump is functioning and
is set for proper output.
4. Check for water in lubricator.
5. Check fuel gas pressure normally 7-12 PSI record CI 4-6 oz. LP.
6. Check EJW temperature (record) 180°F maximum forced system, 206°F
thermosyphon.
7. Check sight level in separator gauge glassel.
8. Check discharge gas temperature maximum 350 F (record).
9. Check RPM of nachine (record).
10. Check exhaust temperatures record) and balance on multi-cylinder units
if they differ more than 40 F.
11. Check fluid level in CJW and EJW system.
12. Check operatiny gas pressures - (record).
13 Check for any abnornal vibration or sounds.
14. Check oil reservoir oil level.
15. If suction or discharge line pressures change check to see if compressor'
cylinder is cleared properly (record).
16. Check to see that all belts are properly tensioned.
17. Check for any loose bolts unit to skid and skid to skid, skid to
foundation, guide to bed, compressor cylinder to guide power cylinder
to bed, etc.
18. Check to see cylinder support is tiyht - not over tight.
19. Check fluid level in gas injection tanks (record any amount added).
20. If interstage pressures change from normal or if capacity drops inspect
compressor valves and replace or repair.
21. Orain any oil from power end scavenging chanber (shutdown mode) record
quantity.
22. Check for any hot compressor valves and recove and replace if danaged
springs and plates are replaced.
23. Check to see that locking screw on cooler bearings is tight.
24. Check to see that switch gauges or shutdown switches are at proper set
point to protect the nachine from overload, or over pressure and over
temperature.
25. Drain any fluid from fuel bottle or fuel header.
26. Check to make assure automatic dump controls and dump valves are properly
functioning.
TD-1344
Page 3 of 5
SCHEDULE "B"
(700 HOURS)
1. Do Schedule "A" maintenance if not done weekly.
2. If you have oil bath air cleaners replace oil in air cleaner with
10 wt. oil (shutdown mode).
3. If dry type air cleaner check manoneter reaainy maximum 1" water column,
clean filters or replace elements.
4. Check for any rod packiny blowby.
5. Drain oil from conpressor end distante piece and record quantity and
observe for any metal flaking.
6. Open condensate drain to oil reservoir and drain off any liquid condensate
that may have formed in tank. SEE ESS-D-761.
8. Crease water punp with one shot of grease.
9. Lubricate each cooler bearing with one shot of grease.
10. Inspect lubricator check valves for leakage.
11. Lubricate injector valve with one shot Whitmores anta-friction

compound #2.
12. Inspect belts for tightness, wear etc., replace if necessary.

TD-1344
Page 4 of 5
SCHEDULE °C"
(5000 HOURS)
1. Inspect spark plugs for proper gap and carbon build up, change if necessary.
2. Remove, inspect and clean compressor valves - replace worn or damaged

parts.
3. Lubricate engine radiator fan. See instruction manual.
4. Lubricate cooler bearings. (one pump with grease gun)
5. Lubricate idler bearings. (one pump with grease gun)
6. Check and replace any broken reed valves in mixer manifold.
7. Check shutdowns for proper operation.
8. Check spark plug wires for spark leakage.
9. Check for debris build up on radiator and/or cooler fins-remove if any.
10. Units that have Partlow switches, remove front cover and lubricate internal
linkage with WD-40 and check switch pointer for freedom of movement.
TD-1344
Page 5 of 5
SCHEDULE "D"
(10,000 HOURS)
1. Change crankcase oil and inspect for any metal, water, etc.
2. Puil power pistuns and inspect:
A. Check for carbon buildup, stuck and broken rings, scuff marks.
B. Remove oid rings and replace
C. Check power cylinder for any wear
3. Clean crankcase breather.
4. Inspect spark plugs and replace if necessary.
5. Replace power cylinder head gaskets.
6. Drain and flush out lubricator.
7. Inspect intake filter screen lubricator pump for dirt build up.
8. Check injector valve seat area and replace if worn.
9. Work shop test alternator, coils.
10. Check water scale buiit up on power cylinder jackets and cooler tubes.
Remove scale if any present.
11. Check running ciearances on crossheads. Crosshead pin bushing and replace
if clearances are excessive.
12. Check power piston rod for any wear or scuff marks (max. .002/inch of rod
diameter undersize)
13. Check fuel injection caros for any excessive wear compressor end (sch.
•
14. Check crosshead piston rod nut for tightness.
15. Check compressor cylinder bore for excessive wear stuffing etc.
16. Change oil wiper packing if necessary.
17. Change compressor stuffing box rings if necessary and inspect compressor
cylinder condition.
18. Change compressor piston rings if necessary.
19. Check compressor cylinder bore for any scuff marks.
20. Check cooler bearings for excessive wear.
21. Change mechanical seal in water pump if leakage occurs.

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Operation

Contract No. 9797

A NOTE indicates an essential operating procedure or condition which must be highlighted.

Cooper Energy Service: III Afax-Superior

General Maintenance Information

Cooper Energy Services ■ Alax-Superior

Coopor Erwrgy Sondees ■ Afax-Superlor

ALL PERSONNEL SHOULD READ AND UNDERSTAND THE PREVIOUS SECTION ON

Cooper Energy Services ■ Ajax-Superior

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER

AS TO THIS SPECIAL EQUIPMENT, WHICH GENERALLY BEARS THE NAMEPLATE

Coosm Energy Services ■ AJax•Suportor

Installation of Sheave and Flywheel

5. Slide hub over shaft to desired position.

Page 1 of 3 Released: 17 October 1996

Part Torque ft-

Page 2 of 3 Releesed: 17 October 199€

Page 3 of 3 Release& 17 October 1996

Keyless Flywheel Installation and Ignition Timing

Page 1 of 4 Released: 6/8/99

Finding TDC and Timing Degree Marks

Page 2 of 4 Released: 6/8/99

Power Cylinder Horizontal

Page 3 of 4 Released: 6/8/99

Setting Timing Of the Flywheel

2804 (DPC-800) Engines Only

Page 4 of 4 Released: 618199

AJAX GAS INJECTION VALVES

YAE-5098-T Series & YAE-5098-Y Series gas injection valve assemblies.

Ajax Mixing Valves

Page 1 of 2 Released: 17 October 1996

Table 2 Valve Manifold Part Numbers

Page 2 of 2 Released: 17 October 199

Spark Plug Lubricant

One of the products that fits these requirements is:

Steps To Follow In The Event Of A Seized Spark Plug

Page 1 of 1 Released: 8/16/99

Instructions For Replacing Lip Seals With Oil Slingers

Page 2 of 3 Released: 8/16199

Page 3 of 3 Released: 8/16/99

DISTRIBUTOR AJAX P.O. NUMBER 0-00-05-004

FUEL GAS SYSTEM

STARTING SYSTEM -(TDD

JACKET WATER SYSTEM

JACKET WATER SYSTEM - (CONT.1

INLET AIR SYSTEM

PROCESS GAS EQUIPMENT

COOLER AND DRIVE

INSTALLATION, START-UP & MAINTENANCE

Bore: is,o Strokt: 16.0

firilig Order: 1 -3 -/ lgoition Ilifig: 1 Elegem BT(

Site Ratiog: std ilorstpower @ 44o RPM

Si/ Cooditions: Ila feet Altitude @ Ha Degrets Fahrenheit

Spred Rige: 164 440 RPM

ADJUSTMENT AND SETTINGS

Shutdowu Settiogof Overspetd Switch: na RPH

Test per Engiatering Standard(s): ES 4018

Winess Test: Tes ti( llo (ertifitd Test Report: Tes xx

Starter Motor Type: Tdi 110 pressure